Maxxforce+13+Manual+de+Servicio.pdf

MaxxForce® 11 and 13 DIESEL ENGINE

SERVICE MANUAL

SERVICE MANUAL

Model Year 2010 and Up MaxxForce® 11 and 13

Model Year 2010 and Up

EGES-465-1

© 2011 Navistar, Inc. All rights reserved. Printed in the United States of America

DIESEL ENGINE

EGES-465-1

ENGINE SERVICE MANUAL

I

Table of Contents

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Cold Start Assist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 Air Compressor and Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 Oil Cooler, Filter Housing and Crankcase Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 Air Intake Throttle Duct and Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 Front Cover, Fan Drive, Cooling System and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283 MaxxForce® Engine Brake by Jacobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315 Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331 Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363 Oil Pan and Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381 Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393 Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409 Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .429

EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

II


Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .443 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449 Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461 Appendix B – Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467 Appendix C – Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487



Foreword Navistar, Inc. is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. This Engine Service Manual provides a general sequence of procedures for out-of-chassis engine overhaul (removal, inspection, and installation). For in-chassis service of parts and assemblies, the sequence may vary. NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information.

1

Technical Service Literature 1171972R3

MaxxForce® 11 and 13 Engine Operation and Maintenance Manual

EGES 465

MaxxForce® 11 and 13 Engine Service Manual

EGES 470

MaxxForce® 11 and 13 Engine Diagnostic Manual

EGED 475

MaxxForce® 11 and 13 Hard Start and No Start and Performance Diagnostic Form

EGED 500

MaxxForce® 11 and 13 Electric Control Systems Diagnostic Form

Technical Service Literature is revised periodically and mailed automatically to “Revision Service” subscribers. If a technical publication is ordered, the latest revision will be supplied. To order technical service literature, contact your International dealer. All marks are trademarks of their respective owners.



2

Service Diagnosis

•

Service diagnosis is an investigative procedure that must be followed to find and correct an engine application problem or an engine problem.

Knowledge of the principles of operation for engine application and engine systems

•

Knowledge to understand and do procedures in diagnostic and service publications

If the problem is engine application, see specific vehicle manuals for further diagnostic information.

Technical Service Literature required for Effective Diagnosis

If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information.

•

Engine Service Manual

•

Engine Diagnostic Manual

•

Diagnostics Forms

•

Electronic Control Systems Diagnostics Forms

•

Service Bulletins

Prerequisites for Effective Diagnosis •

Availability equipment

of

gauges

and

diagnostic

test

•

Availability of current information for engine application and engine systems



Safety Information This manual provides general and specific maintenance procedures essential for reliable engine operation and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible safety conditions and hazards cannot be stated. Read safety instructions before doing any service and test procedures for the engine or vehicle. See related application manuals for more information.

•

3

Restrain long hair.

Vehicle •

Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before servicing engine.

•

Clear the area before starting the engine.

Engine •

The engine should be operated or serviced only by qualified individuals.

•

Provide necessary ventilation when operating engine in a closed area.

•

Keep combustible material away from engine exhaust system and exhaust manifolds.

Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note

•

Install all shields, guards, and access covers before operating engine.

Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe practices that can cause personal injury or death.

•

Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to the engine or vehicle.

Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put protective screens over all openings before servicing engine.

•

Note: A note describes actions necessary for correct, efficient engine operation.

Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps.

•

If an engine is not safe to operate, tag the engine and ignition key.

Safety Instructions

Fire Prevention

Work Area

•

Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or damage to the engine or vehicle. Safety Terminology

•

Keep work area clean, dry, and organized.

•

Keep tools and parts off the floor.

•

Make sure the work area is ventilated and well lit.

•

Make sure a First Aid Kit is available.

Make sure charged fire extinguishers are in the work area.

NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished. 1. Type A — Wood, paper, textiles, and rubbish

Safety Equipment

2. Type B — Flammable liquids

•

Use correct lifting devices.

3. Type C — Electrical equipment

•

Use safety blocks and stands.

Protective Measures •

Wear protective safety glasses and shoes.

•

Wear correct hearing protection.

•

Wear cotton work clothing.

•

Wear sleeved heat protective gloves.

•

Do not wear rings, watches or other jewelry.

Batteries •

Always disconnect the main negative battery cable first.

•

Always connect the main negative battery cable last.

•

Avoid leaning over batteries.

•

Protect your eyes.



4

•

Do not expose batteries to open flames or sparks.

•

Do not smoke in workplace.

Compressed Air •

Use an OSHA approved blow gun rated at 207 kPa (30 psi).

•

Limit shop air pressure to 207 kPa (30 psi).

•

Wear safety glasses or goggles.

•

Wear hearing protection.

•

Use shielding to protect others in the work area.

•

Do not direct compressed air at body or clothing.

Tools

•

Check for frayed power cords before using power tools.

Fluids Under Pressure •

Use extreme caution when working on systems under pressure.

•

Follow approved procedures only.

Fuel •

Do not over fill the fuel tank. Over fill creates a fire hazard.

•

Do not smoke in the work area.

•

Do not refuel the tank when the engine is running.

Removal of Tools, Parts, and Equipment

•

Make sure all tools are in good condition.

•

Make sure all standard electrical tools are grounded.

•

Reinstall all safety guards, shields, and covers after servicing the engine.

•

Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is done.


ENGINE SYSTEMS

5

Table of Contents

Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Engine Emission Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Engine Accessory Labels and Identification Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Heavy Duty On Board Diagnostics (HD-OBD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Chassis Mounted Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Engine Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Air Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Airflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Boost Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Low Pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 High Pressure Charge Air Cooler (HPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 High Pressure Boost Pressure (HPBP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 High Pressure Boost Temperature (HPBT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Low Pressure Boost Pressure (LPBP) Sensor and Low Pressure Boost Temperature (LPBT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Aftertreatment (AFT) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Diesel Oxidation Catalyst (DOC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Aftertreatment (AFT) System Conditions and Responses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Downstream Fuel Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Crankcase Oil Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Fuel Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Fuel Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Low Pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 High Pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Cold Start Assist System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Cold Start Assist System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Cold Start Assist System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Oil Flow and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Cooling System Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Coolant Control Valve (CCV) operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42


6

ENGINE SYSTEMS

Engine Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Engine Brake Control System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Engine Brake System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Electronic Control System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Operation and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Reference Voltage (VREF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Signal Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Microprocessor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Microprocessor Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Actuator Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Exhaust Back Pressure Valve (EBPV) Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Exhaust Gas Recirculation (EGR) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Cold Start Relay (CSR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Cold Start Solenoid (CSS) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Aftertreatment Fuel Doser (AFTFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Aftertreatment Shutoff Valve (AFTSV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Engine and Vehicle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Thermistor Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Variable Capacitance Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Magnetic Pickup Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Potentiometer Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Additional Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Humidity Sensor (HS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52


ENGINE SYSTEMS

Engine Identification

7

Engine Emission Label

Engine Serial Number

Figure 1 1. 2. 3. 4.

Engine serial number

Engine Serial Number (ESN) location Cylinder head Flywheel housing Crankcase

The Engine Serial Number (ESN) is located on the front of the crankcase (left side), below the cylinder head.

Figure 2 2010 U.S. Environmental Protection Agency (EPA) exhaust emission label (example)

MaxxForce® 11: 105HM2XXXXXXX

The U.S. Environmental Protection Agency (EPA) exhaust emission label is on top of the valve cover (front left side). The EPA label typically includes the following:

MaxxForce® 13: 124HM2XXXXXXX

•

Model year

MaxxForce® 11: 105HM2YXXXXXXX

•

Engine family, model, and displacement

MaxxForce® 13: 124HM2YXXXXXXX

•

Advertised brake horsepower and torque rating

Engine Serial Number Codes

•

Emission family and control systems

105 – Engine displacement (10.5 L) 124 – Engine displacement (12.4 L) H – Diesel, turbocharged, Charge Air Cooler (CAC), and electronically controlled M2 – Motor truck Y – Huntsville, Alabama 7 digit suffix – Engine serial number sequence

•

Valve lash specifications

•

ESN

•

EPA, Onboard Diagnostics (OBD), EURO, and reserved fields for specific applications

Engine Serial Number Examples


ENGINE SYSTEMS

8

Engine Accessory Labels and Identification Plates The following engine accessories may manufacturer’s labels or identification plates: •

Air compressor

•

Air conditioning compressor

•

Alternator

•

Cooling fan clutch

•

Engine Control Module (ECM)

•

High pressure (HP) fuel pump

•

Power steering pump

•

Starter motor

•

Turbochargers

have

Engine Specifications MaxxForce® 11 and 13 Diesel Engines Engine Configuration

4 stroke, inline six cylinder diesel

Advertised brake horsepower @ rpm •

MaxxForce® 11

See EPA exhaust emission label

•

MaxxForce® 13


Peak torque @ rpm •

MaxxForce® 11


•

MaxxForce® 13


Displacement •

MaxxForce® 11

10.5 L (641 in³)

•

MaxxForce® 13

12.4 L (758 in³)

Compression ratio •

MaxxForce® 11

16.5:1

•

MaxxForce® 13

17.0:1

Stroke •

MaxxForce® 11

155 mm (6.10 in)

•

MaxxForce® 13

166 mm (6.54 in)

Bore (sleeve diameter) •

MaxxForce® 11

120 mm (4.72 in)

•

MaxxForce® 13

126 mm (4.96 in)


ENGINE SYSTEMS

9

Total engine weight (dry weight without trim or accessories) •

MaxxForce® 11

1087 kgs (2392 lbs)

•

MaxxForce® 13

1087 kgs (2392 lbs)

Firing order

1-5-3-6-2-4

Engine rotation direction (facing flywheel)

Counterclockwise

Aspiration

Dual turbocharged and charge air cooled

Combustion system

Direct injection turbocharged

Fuel system

High pressure common rail

Lube system capacity (including filter) •

MaxxForce® 11

40 L (42 qts)

•

MaxxForce® 13

40 L (42 qts)

Lube system capacity (overhaul only, with filter) •

MaxxForce® 11

44 L (46 qts)

•

MaxxForce® 13

44 L (46 qts)

Engine oil pressure at operating temperature with SAE 15W-40 oil •

Low idle

138-172 kPa (20-25 psi)

•

High idle

448-586 kPa (65-85 psi)

Idle speed (no load)

600 rpm, nominal

Thermostat operating temperature •

Primary

83 °C - 95 °C (181 °F - 203 °F)

•

Secondary

87 °C - 102 °C (189 °F - 216 °F)


ENGINE SYSTEMS

10

Heavy Duty On Board Diagnostics (HD-OBD) The EPA has added new regulations for 2010 to reduce heavy duty vehicle emissions. The HD-OBD system is designed specifically for electronically controlled heavy duty engines. The key goal for HD-OBD regulation is to keep engine emissions in specification for as long as a given vehicle is in use. HD-OBD is legislated to be implemented in three phases: •

2010: First engine for each Original Equipment Manufacture (OEM) becomes fully certified. •

• •

For Navistar®, this is the EPA 2010 MaxxForce® 13 engine.

2013: One engine in each engine family becomes fully certified. •

•

The lead engine is determined by a legislated equation based on projected sales volume & useful life of the engine.

This will be the largest step of the three phases.

2016: All engines must be fully HD-OBD certified.

The HD-OBD system continuously monitors for proper engine operation, and will alert the vehicle operator to emission-related faults using the Malfunction Indicator Lamp (MIL). The MIL is installed in the Electronic Instrument Cluster. When a detected emissions fault occurs, the MIL will be illuminated. Diagnostic information is also stored in the ECM, and may be accessed by the technician for diagnosis and repair of the malfunction. Diagnostic information is accessed by connecting the Electronic Service Tool (EST) to the in-cab Diagnostic Connector.

Engine Description The MaxxForce® 11 and 13 diesel engines are designed for increased durability, reliability, and ease of maintenance. The cylinder head has four valves per cylinder for increased airflow. The overhead valve train includes rocker arms and valve bridges to operate the four valves. The fuel injector is centrally located between the four valves, directing fuel over the piston for improved performance and reduced emissions.

The overhead camshaft is supported by seven bearings in the cylinder head. The camshaft gear is driven from the rear of the engine. The overhead valve train includes roller rocker arms and dual valves that open, using a valve bridge. For 2010, the camshaft has been redesigned to incorporate six additional lobes. These new lobes are used with the engine brake housings for operation of the MaxxForce® Engine Brake. The MaxxForce® 11 engines use aluminum pistons, and the MaxxForce® 13 engines use one piece steel pistons. All pistons use an offset piston axis and centered combustion bowls. Crown markings show correct piston orientation in the crankcase. The one-piece crankcase uses replaceable wet cylinder liners that are sealed by dual crevice seals. The crankshaft has seven main bearings with fore and aft thrust controlled at the sixth bearing. One fractured cap connecting rod is attached at each crankshaft journal. The piston pin moves freely inside the connecting rod and piston. Piston pin retaining rings secure the piston pin in the piston. The rear oil seal carrier is part of the flywheel housing. A gerotor lube oil pump is mounted behind the front cover and is driven by the crankshaft. Pressurized oil is supplied to various engine components. All MaxxForce® 11 and 13 engines also use an engine oil cooler and a cartridge-style engine oil filter, which are located in the engine lube oil module. The low pressure fuel pump draws fuel from the fuel tank(s) through a chassis mounted filter/water separator. The low pressure fuel pump provides fuel for the engine mounted fuel module. Conditioned low pressure fuel is supplied from the engine mounted fuel module to the high pressure fuel pump, cold start fuel solenoid, and the Downstream Injection (DSI) unit. The high pressure fuel system is a direct fuel injected common-rail system. the common-rail includes a high pressure fuel pump, two fuel rail supply lines, fuel rail, six fuel injectors, and pressure relief valve. The fuel injectors are installed in the cylinder head under the valve cover and are electronically actuated by the ECM. MaxxForce® 11 and 13 engines use a dual stage, fixed geometry turbocharger assembly. Each stage includes a pneumatically operated wastegate, and


ENGINE SYSTEMS

Charge Air Cooler (CAC). The Low Pressure Charge Air Cooler (LPCAC) is mounted on the lower right side of the engine, and uses the engine cooling system to regulate charge air temperatures. The High Pressure Charge Air Cooler (HPCAC) is mounted in front of the engine cooling package. The HPCAC is an air-to-air type cooler, and requires no connections to the engine’s cooling system. The Exhaust Gas Recirculation (EGR) system circulates cooled exhaust into the stream in the air inlet duct. The dual stage EGR cooler provides regulated cooling of the EGR gases before entering the air intake duct. This cools the combustion process, and reduces Nitrogen Oxides (NOX) emissions. The open crankcase breather system uses a centrifugal Crankcase Oil Separator (CCOS) to return oil mist to the crankcase, and vent the cleaned crankcase gasses to the atmosphere. The CCOS is part of the oil module. The breather system has been redesigned, and uses no crankcase breather filter or external piping. Blowby gases enter the CCOS directly through the side of the crankcase.

Chassis Mounted Equipment •

The chassis mounted fuel filter/water separator removes a majority of the water and foreign particles that may enter the fuel system from the supply tank(s). This filter works with the engine mounted fuel module to eliminate foreign matter and moisture from the fuel before entering the fuel injection system.

•

The Low Temperature Radiator (LTR) regulates the temperature of the LPCAC and the low temperature stage of the EGR cooler. The LTR is mounted in front of the radiator cooling package, and requires connections to the engine cooling system.

•

The HPCAC lowers the temperature of the after the air is compressed by the turbochargers and has no connections to the engine cooling system. The HPCAC is an air-to-air cooler. The HPCAC is mounted in front of the radiator cooling package.

•

The Diesel Oxidation Catalyst (DOC) oxidizes hydrocarbons and carbon monoxide, provides heat for exhaust system warm-up, aids in temperature management for the Diesel Particulate Filter (DPF), and oxidizes NO into NO2 for passive DPF regeneration. The DOC is monitored by the ECM using one Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor positioned at the DOC inlet, and one Diesel Oxidation Catalyst Outlet Temperature (DOCOT) sensor positioned at the DOC outlet.

•

The DPF temporarily stores carbon-based particulates, oxidizes stored particulates, stores non-combustible ash, and provides required exhaust back pressure for proper engine performance. The DPF is monitored by the ECM using one Diesel Particulate Filter Outlet Temperature (DPFOT) sensor located at the outlet of the DPF, and one Diesel Particulate Filter Differential Pressure (DPFDP) sensor located on or near the DPF.

The cold start assist system warms the incoming air supply prior to and during cranking. The MaxxForce® Engine Brake by Jacobs® is optional for both MaxxForce® 11 and 13 engine displacements. The engine brake is a compression release system that provides additional vehicle braking performance. The operator can control the engine brake for different operating conditions.

Optional Equipment Optional cold climate features available are an oil pan heater and a coolant heater. Both heaters use an electric element to warm engine fluids in cold weather. The oil pan heater warms engine oil to ensure optimum oil flow to engine components. The coolant heater warms the engine coolant surrounding the cylinders. Warmed engine coolant increases fuel economy and aids start-up in cold weather.

11


ENGINE SYSTEMS

12 Engine Component Locations

Figure 3 1. 2.

3. 4. 5.

Component location – top view

Engine coolant inlet Exhaust Gas Recirculation (EGR) cooler (low temperature stage) Air intake duct Air Control Valve (ACV) assembly EGR cooler (high temperature stage)

6. 7. 8.

Pre-DOC assembly EGR Valve (EGRV) Crankshaft Position (CKP) Sensor 9. Air compressor 10. Power steering pump 11. Engine mounted secondary fuel filter access 12. Emission label (location)

13. 14. 15. 16. 17. 18.

Engine oil fill Engine oil level gauge Intake throttle duct assy Engine coolant outlet EGR cooler outlet pipe (coolant) EGR cooler outlet tubes (gases)


ENGINE SYSTEMS

Figure 4 1. 2. 3. 4. 5. 6.

13

Component location – front view

Mass Air Flow (MAF) sensor Air inlet duct EGR cooler EGR Temperature (EGRT) sensor Cold Start Fuel Ignitor Intake Manifold Pressure (IMP) sensor

7. 8. 9. 10. 11. 12. 13.

Charge Air Cooler Outlet Temperature (CACOT) sensor Intake throttle duct assy Thermostat housing HP pump pulley Vibration damper Water engine inlet Water distribution housing.

14. Coolant Control Valve (CCV) 15. HP turbocharger compressor outlet


ENGINE SYSTEMS

14

Figure 5 1. 2. 3. 4. 5. 6.

Component location – left view

EGRT sensor Engine Throttle Valve (ETV) ECM Low Pressure (LP) fuel pressure test port Intake Manifold Temperature (IMT) EGRV

7. 8. 9. 10. 11. 12. 13.

EGR cooler coolant manifold Oxygen Sensor harness Camshaft Position (CMP) sensor Flywheel Housing Air Compressor DSI unit Engine mounted secondary fuel filter access

14. Fuel Delivery Pressure (EDP) sensor 15. Fuel primer pump assembly 16. LP fuel pump 17. HP fuel pump 18. Fuel Rail Pressure (FRP) sensor 19. Intake throttle duct assembly


ENGINE SYSTEMS

Figure 6 1. 2. 3. 4. 5. 6.

15

Component location – right view

EGR cooler coolant manifold HP turbocharger Humidity Sensor (HS) / Air Inlet Temperature (AIT) sensor ACV MAF sensor Engine Coolant Temperature 2 (ECT2)

7. 8. 9. 10.

Oil filter cap EGR Cooler CCV Engine Oil Pressure (EOP) sensor 11. Crankcase Oil Separator (CCOS) 12. LPCAC

13. LP Turbocharger 14. Engine Back Pressure Valve (EBPV) 15. Aftertreatment Fuel Injector (AFTFI) 16. Engine Coolant Temperature 1 (ECT1) sensor


ENGINE SYSTEMS

16

Air Management System

Figure 7 1. 2. 3.

Air Management System

EGRT sensor IMP sensor Charge Air Cooler Outlet Temperature (CACOT)

4. 5. 6.

LP Boost/LP Temperature sensor MAF sensor Humidity Sensor (HS) / Air Inlet Temperature (AIT) sensor

7. 8. 9.

Oxygen Sensor (O2S) Exhaust Valve Intake Valve


ENGINE SYSTEMS Airflow Air flows through the air filter assembly and enters the low pressure turbocharger. The LP turbocharger increases the pressure and temperature of the before entering the LPCAC. Cooled and compressed air then flows from the LPCAC into the HP turbocharger (compressor inlet). Hot and highly compressed air flows from the HP turbocharger (compressor outlet) into the HPCAC where it is cooled, and into the intake throttle duct, and continues through the Engine Throttle Valve (ETV). The HP and LP turbochargers increase pressures up to 345 kPa (50 psi). If the EGRV is open, exhaust gases pass through the EGR cooler and into the intake throttle duct where it is mixed with filtered air. This mixture flows into the intake manifold, and then the cylinder head. The intake manifold is an integral part of the cylinder head casting.

17

After combustion, exhaust gases exit through the cylinder head exhaust valves and ports. The exhaust gas is forced through the exhaust manifold where, depending on EGRV position, it is split between the EGR system and the exit path through the HP turbocharger, LP turbocharger, and EBPV. The EBPV is operated by a pneumatic actuator. When the ACV is applied, the EBPV restricts flow and increases exhaust back pressure. Operation of the EBPV is controlled by the ECM using the ACV and the Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor. When the EBPV is opened, exhaust back pressure is released. Exhaust gases exiting the engine systems flow through the EBPV, then through the vehicle Aftertreatment (AFT) system, and out the exhaust tail pipe.

During cold weather, the cold start assist system rapidly activates the heater element, vaporizing and igniting small quantities of fuel into the air inlet duct.


ENGINE SYSTEMS

18 Turbochargers

Figure 8 1. 2. 3. 4.

High and low pressure turbocharger components – inner and outer views

HP turbocharger compressor inlet HP turbocharger turbine inlet LP turbocharger wastegate actuator HP turbocharger

5. 6. 7. 8. 9.

HP turbocharger wastegate actuator LP turbocharger LP turbocharger turbine outlet Oil supply line Oil return line

MaxxForce® 11 and 13 engines are equipped with a pneumatically regulated two-stage turbocharging system. The HP and LP turbochargers are installed parallel on the right side of the engine. Intake air flow: Filtered air enters the LP compressor, where it is compressed and directed to the LPCAC. Cooled LP air then enters the HP compressor, where it is further compressed and directed into the HPCAC. Compressed air then goes through the ETV and the intake throttle duct. This system provides high charge air pressure to improve engine performance and to help reduce emissions.

10. LP turbocharger compressor outlet 11. LP turbocharger compressor inlet 12. HP turbocharger compressor outlet

Exhaust gas flow: The HP turbocharger is connected directly to the exhaust manifold through the HP turbine inlet. Exhaust gases exit the HP turbine outlet and are directed to the LP turbine inlet. The HP and LP turbochargers are equipped with wastegates, which are controlled by two pneumatic actuators. Individual wastegates are used to regulate boost by controlling the amount of exhaust gases that bypass the turbine of each turbocharger. When boost demand is low, both wastegates are opened, allowing part of the exhaust gas flow to bypass the HP and LP turbines.


ENGINE SYSTEMS

Control system signals associated with the HP and LP turbochargers have been renamed for 2010. All signals related to the LP turbocharger are designated as Turbocharger 1 (TC1) signals, and are identified below: •

Turbocharger 1 Wastegate Control (TC1WC)

•

Turbocharger (TC1TOP)

1

Turbine

Outlet

Pressure

All signals associated with the HP turbocharger are designated as Turbocharger 2 (TC2), and are identified below: •

Turbocharger 2 Wastegate Control (TC2WC)

•

Turbocharger 2 Compressor Inlet Pressure (TC2CIP)

Air Control Valve (ACV)

19

control port, the EBPV control port, and the TC1TOP port. Although these components are integral to the ACV, each circuit is controlled by the ECM. The ACV controls compressed air for each control valve. The air supply port is connected to the vehicle’s air system. The ECM provides a Pulse Width Modulate (PWM) signal for operation of both wastegate control valves. With no PWM signal, the control valves are open, and vehicle air is supplied to the wastegate actuators. The air supplied will maintain both wastegates in the open position. When an increase in the charge air pressure is required, the ECM supplies PWM voltage to close both control valves. Reduced air pressure is routed from the closed air control valves to the wastegate actuators causing the wastegate to close and vent air pressure. This results in increased charge air pressures. The limit values of the PWM signals are between approximately 9%, corresponding to a fully opened air control valve, and 100% corresponding to a closed air control valve. The TC1TOP sensor and EBPV control valve are in the ACV. The EBPV control valve is also operated by the ECM using PWM, and the TC1TOP sensor is monitored by the ECM. The EBPV control valve operates the EPBV actuator.

Boost Control

Figure 9 1. 2. 3. 4. 5. 6.

Air Control Valve (ACV) connections

Electrical connector LP turbocharger wastegate control port Vehicle air supply port EBPV control port TC1TOP sensor port HP turbocharger wastegate control port

The ACV assembly contains the LP turbocharger wastegate control port, HP turbocharger wastegate

Wastegate control valves, in the ACV, provide for operation of a pneumatic wastegate actuator for each turbocharger. Boost is controlled for each turbocharger independently, by signals sent from the ECM to the ACV. In normal operation the wastegates are actuated by the ACV using vehicle compressed air, regulated to 296 kPa (43 psi). Positioning of the wastegates by the ACV is based on boost pressure and temperature signals monitored by the ECM. Because of the ability to generate very high charge air pressure levels and to avoid Charge Air Cooler (CAC) overloading, the wastegate actuator for each turbocharger is also spring loaded. When boost levels increase above specification, boost pressure alone will open the wastegates, and the exhaust gases will bypass the turbochargers. Exhaust back pressure is constantly monitored by the ECM using TC1TOP. The TC1TOP sensor is part of the ACV, and is connected to the exhaust system by a steel line.


20

ENGINE SYSTEMS

Low Pressure Charge Air Cooler (LPCAC) The LPCAC is installed between the HP and LP turbochargers, and is mounted to the lower right side of the engine. The LPCAC air inlet is connected to the low pressure turbocharger compressor outlet, and uses engine coolant to regulate the LP charge air temperature. The LPCAC air outlet is connected to the compressor inlet of the HP turbocharger.

High Pressure Charge Air Cooler (HPCAC) The HPCAC is installed between the HP turbocharger and the intake throttle duct. The HPCAC air inlet is connected to the HP compressor outlet, and uses ambient airflow entering the front of the vehicle to reduce the charge air temperature. The HPCAC air outlet is connected directly to the intake throttle duct.

input to the engine coolant control strategy. It also is used for evaluation of on-board diagnostics to ensure proper functionality of the charge air cooling system. This temperature sensor is a thermistor and has two connections to the ECM. A thermistor varies resistance as temperature changes. When interfaced to the ECM circuitry, a change in sensor resistance results in a voltage change internal to the ECM. A transfer function contained in the ECM software translates the measured voltage to a temperature value. The ECM continuously monitors the voltage resulting from the thermistor’s changing resistance. High and low diagnostic voltage thresholds are evaluated to ensure that the output voltage is within a valid range.

Low Pressure Boost Pressure (LPBP) Sensor and Low Pressure Boost Temperature (LPBT) Sensor High Pressure Boost Pressure (HPBP) Sensor This sensor monitors the pressure of the charge air entering the duct. The primary function of the sensor is to provide information used to ensure proper boost control. It is also used as part of EGR control. Pressure sensor works by providing an analog voltage output to the ECM which is proportional to pressure being applied to an internal diaphragm in the sensor. The sensor is connected to the control module through the Reference Voltage (VREF), signal, and signal ground wires. A transfer function contained in the ECM software converts the analog voltage to a pressure value which is then used by software strategies requiring the pressure information. The ECM continuously monitors the pressure sensor output voltage for determination of charge air pressure. High and low diagnostic voltage thresholds are evaluated to ensure that output voltage is within a valid range.

High Pressure Boost Temperature (HPBT) Sensor This sensor monitors the temperature of the charge air entering the duct. The temperature measured is an

This is a combination pressure and temperature sensor. This sensor is a dual function sensor that detects pressure and temperature of the charge air entering the HP compressor. It is installed in the piping between the LP compressor outlet and the HP compressor inlet. This sensor is used for evaluation by on-board diagnostics to ensure proper functionality of the charge air cooling system. This sensor consists of a thermistor which varies resistance as temperature changes. When interfaced to the ECM circuitry, a change in sensor resistance results in a voltage change internal to the ECM. An internal diaphragm which deflects due to pressure changes results in an analog voltage output to the ECM which is proportional to the pressure. Transfer functions contained in the ECM software translate the measured voltages into a temperature and a pressure value. The ECM continuously monitors the voltages resulting from changes in both the temperature and pressure. High and low diagnostic voltage thresholds are evaluated to ensure that the output voltage is within a valid range.


ENGINE SYSTEMS

21

Exhaust Gas Recirculation (EGR) System

Figure 10 1. 2. 3. 4. 5.

EGR system components

EGRT sensor EGR cooler air bleed (to deariation tank) EGR cooler (low temperature stage) EGRV coolant return line (to deariation tank) High temperature EGR cooler

6. 7. 8. 9.

Intake Manifold Temperature (IMT) EGR cooler outlet tube (2) (gases) Low temperature EGR cooler inlet (coolant) Engine Coolant Temperature 2 (ECT2) sensor

10. Low temperature EGR cooler outlet (coolant) 11. EGRV coolant supply line 12. EGR cooler inlet tubes (gases) 13. EGRV 14. EGR cooler inlet (coolant)


ENGINE SYSTEMS

22 EGR System Overview

The EGR system reduces NOX engine emissions by introducing inert cooled exhaust gas into the air inlet duct. NOX forms during a reaction between nitrogen and oxygen at high temperatures during combustion. The ECM monitors signals from the CACOT sensor, Oxygen sensor (O2S), Engine Coolant Temperature 1 (ECT1) sensor, EGRT sensor to control the EGR system. EGR is switched off (EGRV closed) if any of the following conditions are present: •

Engine coolant temperature less than 10 °C (50 °F) will close the EGR valve

•

Intake manifold temperatures less than 7 °C (45 °F) will close the EGR valve

•

During engine brake operation

monitors and provides an EGRV position signal to the ECM. The O2S is installed in the exhaust, in front of the aftertreatment fuel injector. The O2S has a heater element that heats the sensor to its normal operating temperature of 780 °C (1436 °F). During initial engine warm-up, the O2S heater element is activated only after the engine coolant reaches 40 °C (104 °F) and the exhaust gas temperature DOCIT sensor exceeds 100 °C (212 °F) for more than 30 seconds. EGRV Control

EGR Flow Exhaust gas from the exhaust manifold flows through the EGR inlet tubes to the EGRV. When EGR function is activated, the EGRV opens and allows exhaust gas to enter the EGR cooler. Cooled exhaust gas flows from the front of the EGR cooler, through the EGR outlet tubes, and into the intake throttle duct where it is mixed with filtered air. EGR System Control The EGR system consists of the EGRV, ETV, and O2S. The EGRV contains a PWM controlled valve and Exhaust Gas Recirculation Position (EGRP) sensor. The EGRV is installed at the rear of the EGR cooler, on the right side of engine valve cover. The EGRV limits exhaust gas flow into the EGR cooler. The ECM commands the EGRV to move and hold position. The EGRP sensor, located inside the EGRV,

Figure 11 1. 2. 3. 4. 5. 6. 7.

EGRV position control

EGR position monitored by ECM ECM ECM commands EGR to desired position EGRV to desired position EGRV EGRV position matches ECM command EGR position sent to ECM

The EGRV has an integrated position sensor, and provides feedback to the ECM indicating EGRV position.


ENGINE SYSTEMS

23

EGR – Open Loop

EGR Flow Cooling

During the engine warm-up period and before the O2S reaches its normal operating temperature, the EGR system operates in open loop. In open loop, the EGR system is controlled by the ECM based on the charge air temperature, engine coolant temperature, engine speed, and load conditions.

The EGR system includes a two-stage EGR cooler, allowing the ECM to regulate EGR Cooler temperatures. The ECM monitors intake manifold temperature through the Exhaust Gas Recirculation Temperature 1 (EGRT1) sensor and to regulate EGR flow temperatures, the CCV regulates coolant flow through the LTR. Refer to Cooling System in this section for more information.

EGR – Closed Loop After the O2S reaches its operating temperature, the EGR system switches to closed loop operation. In closed loop, the EGR system is controlled by the ECM based on coolant temperature and O2S readings.


ENGINE SYSTEMS

24 Aftertreatment (AFT) System

Figure 12 1. 2. 3.

AFT system overview

Pre-DOC exhaust flow Aftertreatment Fuel Injector (AFI) DOC

4. 5. 6. 7.

DPF Exhaust out to tail pipe DPFOT sensor DPFDP sensor

The AFT system, part of the larger exhaust system, processes engine exhaust to meet emission requirements. The AFT system traps particulate matter (soot) and prevents it from leaving the tailpipe. The AFT system performs the following functions: •

Monitors exhaust gas temperatures DOC in, DOC out, and DPF out temperature and delta pressure across the DPF. It controls engine operating parameters for emission control and failure recognition

8. 9.

DOCOT sensor DOCIT sensor

•

May cancel regeneration in the event of catalyst or sensor failure

•

Monitors the level of soot accumulation in the DPF

•

AFT control system initiates regeneration automatically when DPF is full with soot and control engine operating parameters to increase temperature to have successful regeneration

•

Maintains vehicle and engine performance during regeneration


ENGINE SYSTEMS

25

Diesel Particulate Filter (DPF)

•

Provides heat for exhaust system warm-up

The DPF does the following:

•

Aids in system temperature management for the DPF

•

Captures and temporarily stores carbon-based particulates in a filter

•

Allows for oxidation (regeneration) of stored particulates once loading gets to a particular level (restriction)

•

Provides the required exhaust back pressure drop for engine performance

•

Stores non-combustible ash

Aftertreatment (AFT) System Conditions and Responses The operator is alerted of system status either audibly or with instrument panel indicators. Automatic or manual regeneration is required when levels of soot exceed acceptable limits. For additional information, see the applicable vehicle Operator’s Manual and the vehicle visor placard.

Diesel Oxidation Catalyst (DOC) The DOC does the following: •

Oxidizes hydrocarbons and carbon monoxide (CO) in exhaust stream


ENGINE SYSTEMS

26 Downstream Fuel Injection

Figure 13 1.

Downstream fuel injection components

DSI unit

2.

Fuel line retainers (rear of engine block)

The DSI system injects fuel into the exhaust system to increase temperature of the exhaust gases, and is necessary for DPF regeneration. DSI is controlled by the ECM. The ECM receives signals from the Aftertreatment Fuel Doser (AFTFD) sensor (located in

3. 4.

AFI AFI fuel pressure line

the DSI unit), and control operation when downstream injection (regeneration) is required. The ECM also controls the Aftertreatment Shutoff Valve (AFTSV) (located in the DSI unit) which controls the volume of fuel sent to the AFI in case of AFTFD malfunction.


ENGINE SYSTEMS Downstream Injection (DSI) Unit

27

The DSI unit is connected to the clean side of the low pressure fuel system, and will provide a metered amount of fuel to the AFI. The DSI unit provides pressurized fuel injection pulses to the AFI. The AFI is a mechanical poppet type injector, and will only inject fuel when fuel line pressure is increased above a specific pressure. The DSI unit is installed on the left side of the engine, to the rear of the fuel module. The AFTFIS and AFTFP2 sensors monitor fuel pressure and temperature in the DSI system, and provide constant feedback to the ECM. Aftertreatment Fuel Injector (AFI) The AFI is located on the right side of the engine, and is installed in the turbocharger exhaust pipe after the exhaust O2S.

Figure 14 1. 2. 3. 4. 5. 6.

Downstream Injection (DSI) unit

Fuel supply from fuel filter assembly Aftertreatment Fuel Inlet (AFTFIS) sensor Aftertreatment Fuel Pressure 2 (AFTFP2) sensor High pressure fuel outlet electrical connector to AFI Fuel out electrical connector to AFI Fuel outlet port to AFI

Pressurized fuel is supplied to the injector by the DSI unit using the AFTFD valve. When the conditions required for regeneration are met, the ECM sends a PWM voltage to the AFTFD. During operation, the AFTFD increases fuel pressure to the AFI, causing injection of fuel into the exhaust pipe. To protect the AFI internal components, continuous engine coolant flow through the AFI is maintained by external coolant supply and return lines.


ENGINE SYSTEMS

28 Crankcase Oil Separator

Figure 15 1. 2. 3. 4.

Oil Module w/Crankcase Oil Separator

Coolant supply line CCOS vent tube Crankcase Oil Separator Speed (CCOSS) sensor Crankcase Centrifuge Oil Separator (CCOS)

5. 6. 7. 8.

Oil filter access cap Engine Oil Temperature (EOT) sensor Engine Oil Pressure (EOP) sensor Coolant return line

9.

CCOS ventilation tube heater


ENGINE SYSTEMS

Crankcase ventilation is provided using the CCOS. Excess crankcase vapors are filtered by the CCOS, and are then vented to the atmosphere. A centrifugal oil separator, driven by engine oil pressure, separates and directs oil mist to the side of

29

CCOS housing. The separated oil mist drains from the oil separator, through the crankcase, and into the oil pan. The oil separator is an integral part of the oil module.


ENGINE SYSTEMS

30

Fuel Management System

Figure 16 1. 2. 3. 4. 5.

Fuel system

Injector (6) Fuel Rail Fuel rail pressure relief valve Fuel return from cylinder head Engine fuel return connection (to chassis filter)

6. 7. 8. 9. 10.

Fuel supply to DSI unit Fuel return line Fuel filter assembly Drain screw Engine Fuel Pressure (EFP) sensor

MaxxForce® 11 and 13 engines are equipped with a high pressure common rail injection system. The common rail fuel injection system provides pressurized fuel to the fuel injectors for optimal fuel atomization in the combustion chamber.

11. 12. 13. 14.

Fuel primer pump assembly LP fuel pump HP fuel pump Fuel Rail Pressure (FRP) sensor

The fuel system is controlled by the ECM, various sensors, and the Fuel Pressure Metering Unit (FPMU) located in the HP pump. For additional information, refer to LP Fuel System and HP Fuel System in this section.

All excess fuel is returned to the chassis mounted filter separator, before returning to the fuel tank.


ENGINE SYSTEMS

31

Fuel Flow

Figure 17 1. 2. 3. 4. 5.

Fuel supply flow diagram

Fuel Return Fuel supply Fuel tank Chassis mounted fuel filter/water separator (Top portion) Fuel primer pump assembly w/fuel strainer element

6. 7.

LP fuel pump Fuel filter assembly (engine mounted) 8. DSI unit 9. HP fuel pump 10. Cold Start Fuel Solenoid (CSFS) 11. Fuel rail

Fuel is pumped from the tank, through the chassis mounted fuel filter/water separator using the LP fuel pump. Fuel is pumped from the LP fuel pump to the engine mounted fuel filter assembly, before being supplied to the HP fuel pump. The high pressure fuel

12. Fuel injectors 13. Chassis mounted fuel filter/water separator (bottom portion)

pump supplies high pressure fuel to the fuel rail, which feeds the injectors through individual tubes. The LP fuel pump and HP fuel pump are assembled as one gear driven unit, and are serviced as an assembly.


ENGINE SYSTEMS

32 Low Pressure Fuel System

Figure 18 1. 2. 3. 4. 5. 6. 7. 8.

Low pressure (LP) fuel system

HP fuel pump Fuel Pressure Control Valve (FPCV) Fuel primer pump assembly w/ fuel strainer element Fuel pressure test port Engine fuel supply connection EFP sensor Engine mounted secondary fuel filter access Engine fuel return connection

9. Fuel supply to DSI unit 10. Chassis mounted primary fuel filter access 11. Fuel supply to engine 12. Fuel return from engine 13. Fuel supply from tank 14. Chassis mounted fuel filter/water separator 15. Fuel Heater 16. Water In Fuel (WIF) sensor 17. Fuel return to tank

The LP fuel pump pumps fuel from the tank through the chassis mounted fuel filter/water separator, fuel strainer element and engine filter element, then to the high pressure fuel system, cold start assist system, and DSI. In addition to providing high pressure fuel to the injectors, the fuel system provides filtered low pressure fuel to the downstream Injection and cold start assist systems. Chassis Mounted Filter/Water Separator The chassis mounted filter/water separator removes debris and water from the fuel before it enters the fuel primer pump and low pressure fuel pump. The chassis mounted filter/water separator includes a

18. 19. 20. 21. 22. 23. 24. 25. 26.

Fuel return from engine Fuel supply to engine Engine mounted fuel module Cold start assist port Low pressure fuel supply line LP fuel pump outlet LP fuel pump inlet HP fuel pump inlet HP fuel pump return

Water In Fuel (WIF) sensor and optional fuel heater. Refer to Section 5 “Chassis Filter/Water Separator Maintenance and Inspection” in this manual for more information. Fuel Primer Pump Assembly During fuel system priming, fuel is drawn from the tank through the chassis mounted filter/water separator by the fuel primer pump assembly. The fuel primer pump assembly has an integrated fuel strainer element that can be cleaned. The fuel primer pump assembly is manually operated, and is used to prime the low pressure fuel system anytime the fuel system has been emptied. The primer pump provides unrestricted fuel flow to the low pressure pump during normal engine operation.


ENGINE SYSTEMS Low Pressure (LP) Fuel Pump The LP fuel pump and the HP fuel pump are housed as one assembly. Fuel is drawn through the fuel primer pump assembly and into the LP fuel pump. The LP pump supplies fuel to the fuel filter housing assembly at pressures varying between 496 kPa (72 psi) at idle, and 896 kPa (130 psi) at rated speed. The LP fuel pump is equipped with an internal pressure regulator that relieves the fuel pressure internally if the pressure exceeds 1300 kPa (189 psi). Fuel Filter Assembly The fuel filter assembly is located on the left side of the engine and has a disposable filter element. An EFP sensor is installed on the front side of the fuel filter

33

assembly, which measures fuel pressure between the LP fuel pump and the filter element. The fuel filter assembly also has a drain screw that allows water and dirt to be drained periodically. Because water may accumulate inside the fuel filter assembly, use the drain screw to drain water per maintenance schedule in the Engine Operation and Maintenance Manual. An additional function of the fuel filter assembly is fuel system self-deaeration. The air separated from fuel is pushed back into the fuel tanks through the return line. The fuel filter assembly also provides filtered fuel to the DSI and cold start assist system. An orifice regulator is integrated into the fuel filter assembly, and regulates the fuel pressure for the cold start assist system to 70 kPa (10 psi).


ENGINE SYSTEMS

34 High Pressure Fuel System

Figure 19 1. 2. 3.

High pressure (HP) fuel system

Injector (6) Rail pressure relief valve Fuel Rail

4. 5.

Fuel Pressure Control Valve (FPCV) Fuel inlet - HP fuel pump

Pressurization and injection are separate in the common rail injection system. The optimal injection pressure is generated by the high pressure pump at any engine speed. High pressure fuel quantity from high pressure pump is controlled by the FPCV. The injection timing and quantity are calculated in the ECM and implemented by solenoid valve controlled injectors. The use of solenoid valve controlled injectors allows three injections per cycle. The first injection is used to reduce combustion noise and emissions by introducing a small amount of fuel into the cylinder, preventing a rapid rise

6. 7. 8.

Fuel return - HP fuel pump HP fuel pump FRP sensor

in cylinder pressure when combustion begins. The second injection is the main injection. This injection allows high temperatures to be maintained during combustion, but not long enough to allow generation of large soot amounts. The third injection is done during the power stroke to maximize cylinder temperature and reduce engine soot generation. The high pressure fuel system consists of the high pressure pump with integrated Fuel Pressure Metering Unit (FPMU), pressure pipe rail, high pressure fuel lines, injectors, FRP sensor, and pressure relief valve.


ENGINE SYSTEMS

35

High Pressure (HP) Pump

Injectors

The HP pump supplies the necessary quantity of HP fuel for all operating engine modes. The HP pump is gear driven and is fuel lubricated. Fuel from the LP fuel pump is forced through the fuel module assembly, and into the HP pump. The flow of fuel to the suction chamber of the HP pump is controlled by the FPCV, in order to control HP fuel output.

MaxxForce® 11 and 13 engines are equipped with electronically controlled injectors. During engine operation, injectors are supplied at all times with high pressure fuel, and the injector solenoid valves open up to three times per cycle. The injectors are positioned vertically in the center of the cylinder head and are held in place by brackets. The seal between the injectors and the combustion chamber consists of a copper washer on the tip of each injector.

Fuel Pressure Control Valve (FPCV) The FPCV is a variable position actuator installed on the suction side of the high pressure pump and controls the output fuel pressure. The ECM sends a PWM signal to control the FPCV. A 100% duty cycle PWM signal corresponds to minimum fuel pressure delivery, while a 0% duty cycle PWM corresponds to maximum fuel pressure delivery.

Cold Start Assist System Cold Start Assist System Components

Fuel Rail The fuel rail is a HP fuel storage unit. The storage volume of the fuel rail is designed to reduce pressure pulses caused by the HP pump and injectors, and to maintain constant fuel pressure even when large fuel quantities are injected into the cylinders. Connection between the fuel rail and injectors are made through two individual injection lines. Fuel Rail Pressure (FRP) Sensor The FRP sensor is a variable resistance sensor that monitors fuel pressure in the HP fuel rail. The FRP sensor is mounted in the front of the fuel rail, on the left side of the engine. Rail Pressure Relief Valve The rail pressure relief valve maintains fuel pressure inside the fuel rail below 260,000 kPa (37,710 psi). If HP pump output exceeds 260,000 kPa (37,710 psi), the pressure relief valve opens and allows fuel to flow into the fuel return line. With the pressure relief valve open, fuel pressure in the pressure pipe rail drops to approximately 110,000 kPa (15,954 psi).

Figure 20 1. 2. 3.

Cold start assist system

Cold Start Fuel Ignitor (CSFI) Cold Start Solenoid (CSS) valve Cold Start Relay (CSR)

Cold Start Fuel Ignitor (CSFI) The cold start assist system rapidly activates the heater element, vaporizing and igniting small quantities of fuel into the air inlet duct.


ENGINE SYSTEMS

36

Cold Start Solenoid (CSS) Valve The CSS valve is located on the left side of the engine and is controlled by the ECM. The CSS valve is supplied with low fuel pressure regulated fuel from the fuel filter assembly. When the ECM provides battery voltage to the CSS valve, the solenoid opens and allows fuel to flow to the CSFI through the CSFI fuel line.

Cold Start Assist System Operation The cold start assist system operates only in temperatures lower than 10 °C (50 °F). Figure 21 Cold Start Fuel Ignitor (partial cut away view) 1. 2. 3. 4. 5. 6. 7. 8.

Electrical connection Insulation CSFI fuel line connection Metering device Vaporizer filter Vaporizer tube Heater element Protective sleeve

The CSFI has an internal fuel metering device, a vaporizer filter, a vaporizer tube, a heater element, and a protective sleeve. The protective sleeve has holes that allow enough air to pass through the CSFI to enable fuel vaporization and combustion. The CSFI is installed on the left front side of the engine, in the intake throttle duct. Cold Start Relay (CSR)

When the truck operator turns the ignition switch to ON, the wait-to-start lamp in the instrument cluster illuminates. Based on the temperature readings from the ECT, the ECM activates the CSR heater element. The CSR then energizes the CSFI for approximately 35 seconds. Once the CSFI is heated to approximately 1000 °C (1832 °F), the wait-to-start lamp starts to flash and the operator needs to crank the engine. When the engine starts rotating, the CSS valve opens and allows fuel to enter the CSFI. Inside the CSFI, fuel passes through the vaporizer tube. The vaporized fuel then mixes with in coming air and ignites in contact with the heater element. Once the engine starts, the CSFI remains energized and fuel continues to be injected, and the wait-to-start lamp continues to flash for a maximum of four minutes. When the wait-to-start lamp stops flashing, the CSFI and the CSS valve are deactivated. If the operator accelerates while the wait-to-start lamp is flashing, the cold start assist system will shutdown.

The CSR is located on the left side of the engine at the rear of the ECM. The CSR provides voltage to the CSFI, and is controlled by the ECM.


ENGINE SYSTEMS

37

Oil Flow and Components

Figure 22 1. 2. 3. 4. 5. 6.

Oil flow

Oil filter element Oil return from cylinder head Oil supply to exhaust valve bridge Oil supply to rocker gear Oil supply to camshaft bearings Oil supply to intermediate gears

7. 8.

Oil supply to air compressor Oil supply to crankshaft main bearings 9. Oil supply to piston oil sprayer nozzles 10. Oil supply to turbochargers 11. Oil supply to drive housing

Unfiltered oil is drawn from the oil pan through the pickup tube and front cover passage by the crankshaft driven gerotor pump. The pressurized oil is moved through a vertical crankcase passage and into the oil module. Inside the oil module, unfiltered oil flows through plates in the oil cooler heat exchanger. Engine coolant

12. 13. 14. 15. 16. 17.

Oil supply to front cover Oil pump output Oil pressure relief valve Oil supply to oil module Oil return shutoff valve Oil cooler

flows around the plates to cool the surrounding oil. An oil return shutoff valve installed at the exit from the oil cooler prevents oil from draining through the oil pump and back into the oil pan when the engine is stopped. If oil pressure coming out of the oil pump is too high, a pressure relief valve allows the excess oil to return through the crankcase and into the oil pan before entering the oil cooler.


38

ENGINE SYSTEMS

Oil that exits the oil cooler flows through a return shutoff valve that prevents the oil from draining back into the oil pan. From the return shutoff valve, oil enters the oil filter element and flows from the outside to the inside of the filter element to remove debris. When the filter is restricted, an oil filter bypass valve opens and allows oil to bypass the filter so engine lubrication is maintained. If the oil pressure inside the oil filter element is too high, an oil pressure relief valve, located at the bottom of the oil filter element housing, allows the excess oil to return to the oil pan. After passing through the oil filter element, oil flow is directed to the cylinder head and crankcase. Clean oil enters the cylinder head through an external flange elbow connected directly to the oil module. Inside the cylinder head, oil flows through passages to lubricate the camshaft bearings, rocker arms, exhaust valve bridges, and cylinder intermediate gear. Clean oil enters the crankcase directly from the oil module to lubricate the crankshaft, high pressure

pump, air compressor, intermediate gears, and turbochargers. The crankshaft has cross-drillings that direct oil to the connecting rods. Oil sprayer nozzles continuously direct cooled oil to the bottom of the piston crowns. The turbochargers are lubricated with filtered oil from an external supply tube that connects the main oil gallery from the crankcase to the center housing of each turbocharger. Oil drains back to the oil pan through the low and high pressure turbocharger oil return pipes connected to the crankcase. A service oil drain valve, located at the bottom of the filter element cavity, opens automatically when the filter element is lifted for replacement, and allows the oil from the oil filter element cavity to drain into the oil pan. Oil is also supplied to the MaxxForce® Engine Brake housings (under valve cover) through specially designed rocker mounting bolts.


ENGINE SYSTEMS

39

Crankcase Oil Separator

Figure 23 1. 2. 3. 4. 5. 6.

Oil module w/crankcase oil separator assembly (inner and outer views)

CCOS CCOS vent outlet CCOSS sensor Filter cover Oil filter assembly EOT sensor

7. 8. 9. 10. 11. 12.

Oil return from cylinder head Oil supply to cylinder head Crankcase gas inlet Oil cooler inlet Oil supply from oil pump Regulator

The oil module contains a canister style filter, oil cooler, EOP and EOT sensors, a pressure relief valve, an oil filter bypass valve, and an oil return shutoff valve. The oil module also collects, and then

13. 14. 15. 16. 17.

CCOS oil return Oil module pressure relief port Oil out to crankcase Oil cooler outlet to crankcase EOP sensor

directs crankcase emissions to the CCOS. The oil that separates from the crankcase emissions, before it reaches the CCOS, is drained back into the oil pan through the oil return port.


ENGINE SYSTEMS

40

Engine Cooling System Cooling System Flow

Figure 24

Cooling system flow


ENGINE SYSTEMS

The water pump is installed on the water distribution housing and draws coolant from the radiator through the coolant inlet. MaxxForce® 11 and 13 engines have no coolant passages between the crankcase and cylinder head through the cylinder head gasket. This eliminates the possibility of coolant leaks at the cylinder head gasket. Coolant in and out of the crankcase and cylinder head is directed through external passages. Coolant flows through the crankcase and cylinder head from front to rear. This coolant flows around the cylinder liners and combustion chambers to absorb heat from combustion. Coolant exiting the crankcase and cylinder head at the rear of the engine is directed through an external coolant pipe to the high temperature stage of the EGR cooler. Coolant passes between the EGR cooler plates, travels parallel to the exhaust flow, travels through a transfer passage in the left side of the low temperature EGR cooler, into the EGR cooler return manifold and into the thermostat housing. A deaeration port on the top of the high temperature EGR cooler directs coolant and trapped air to the coolant surge tank. Coolant from the water pump also flows through the low temperature EGR Cooler and then through the LPCAC to regulate the charge air temperature. Flow through the low temperature EGR cooler/charge air cooler is controlled by the Coolant Mixer Valve (CMV) and Coolant Flow Valve (CFV). Depending on the coolant flow, CMV sends coolant through the low temperature EGR Cooler, or bypass indirectly to the LPCAC, after going through the LTR located in front of the main coolant radiator. When the charge air temperature is too low, CMV bypasses the LTR and directs all the coolant through the CAC. When the charge air temperature increases, CMV directs a percentage of the coolant to the LTR before it enters the CAC to cool the charge air. If the engine coolant temperature is too high, CMV sends all of the coolant flow through the LTR and through the LPCAC to help cool the engine faster. Both CMV and CFV are controlled by the ECM based on signals from the Engine Coolant Temperature (ECT) sensor, ECT2 sensor, and the Intake Manifold Pressure (IMP)/Air Inlet Temperature 2 (MAP/AIT2) sensors.

41

Coolant flow to the radiator is controlled by two thermostats. When the thermostats are closed, coolant flowing out of the EGR cooler is directed through a bypass port inside the front cover into the water pump. When the thermostats are open the bypass port is blocked, and coolant is directed from the engine into the radiator. Coolant passes through the radiator and is cooled by air flowing through the radiator from ram air and operation of the coolant fan. The coolant returns to the engine first through the transmission cooler, then through the engine coolant inlet elbow. The air compressor is cooled with coolant supplied by a hose from the left side of the crankcase. Coolant passes through the air compressor cylinder head and returns through a coolant return line to the engine crankcase. The oil module receives coolant from a passage in the crankcase. Coolant passes between the oil cooler plates and returns back to the water pump suction passage.

Thermostat Operation MaxxForce® 11 and 13 engines are fitted with two thermostats in a common housing to ensure sufficient coolant flow in all operating conditions. The thermostat housing is installed on top of the water distribution housing. The thermostat housing assembly has two outlets. One directs coolant to the radiator when the engine is at operating temperature. The second outlet directs coolant to the water pump until the engine reaches operating temperature. The thermostats begin to open at 83 °C (181 °F) and are fully open at 91 °C (196 °F). When engine coolant is below 83 °C (181 °F), the thermostats are closed, blocking coolant flow to the radiator. When coolant temperature reaches the opening temperature of 83 °C (181 °F), the thermostats open allowing some coolant to flow to the radiator. When coolant temperature exceeds 91 °C (196 °F), the lower seat blocks the bypass port directing full coolant flow to the radiator.


ENGINE SYSTEMS

42 Coolant Control Valve (CCV) operation

The CCV is installed on the upper right side of the water distribution housing and controls the coolant flow to the CACs. The CCV has two separate solenoid actuated valves based on the charged air temperature and the two engine coolant temperature sensors; CMV, and CFV. The CMV and the CFV are part of the CCV assembly and cannot be serviced separately. The CMV and CFV solenoids are controlled by two separate PWM signals from the ECM. The PWM signal duty cycles vary between 0% and 100% depending on the coolant and charge air temperature. Coolant Flow Valve (CFV)

LPCAC. The CFV will close to reduce the coolant flow through the LPCAC when the engine is operating at high speeds. Coolant Mixer Valve (CMV) The CMV is installed on the upper side of CCV and controls the coolant flow through the LTR. When the temperature of the charge air and coolant coming out of the LPCAC is low, the CMV directs the coolant through a LTR bypass directly into the LPCAC. This helps the engine reach its normal operating temperature faster. If the temperature of the charge air and coolant coming out of the LPCAC is high, the CMV directs the coolant flow through the LTR. This prevents overheating of the LPCAC, which can result in LPCAC failure.

The CFV is installed on the lower side of CCV and controls the amount of coolant flow through the


ENGINE SYSTEMS

43

Engine Brake System Engine Brake Control System Components

Figure 25 1. 2. 3. 4. 5.

Engine brake control system components

Upper valve cover Injector harness connector Engine brake solenoid harness connector lead (2) Pass through harness ECM E1 connector

6. 7. 8. 9.

Master piston roller assembly (3 each housing) Engine brake master piston (within housing) Exhaust valve bridge Engine brake slave piston

10. Valve cover base 11. Engine brake solenoid (1 each housing) 12. Engine brake housing assembly (2)


ENGINE SYSTEMS

44

The MaxxForce® Engine Brake by Jacobs® braking system is standard equipment on the PROSTAR® and optional equipment on the TRANSTAR® and WORKSTAR® for the MaxxForce® 11 and 13 engines. The braking system is a hydro-mechanical device that mounts under the engine’s valve cover. It turns your power-producing diesel engine into a power-absorbing air compressor. Here’s how: when the driver releases the accelerator pedal, the forward momentum of the truck continues to turn the drivetrain and engine. The pistons continue to move up and down. Once activated, the engine brake opens the exhaust valves near the peak of the compression stroke, releasing the highly compressed air through the exhaust systems. Little energy is returned to the piston, and as the cycle repeats, the energy of the truck’s forward motion is now directed toward motoring the diesel engine, thus reducing the forward motion causing the truck to slow down. Engine Brake System Operation The engine brake system consists of two hydraulic braking housings, activated using two ECM actuated brake solenoids, and an exhaust bridge (pin). The engine brake depends on engine oil for operation; minimum oil temperature for engine brake activation is 40 °C (104 °F). The operation of the engine brake is fully automatic once it is turned on by an ON/OFF switch by the operator. When the clutch is fully engaged and you remove your foot completely from the throttle, the engine brake is automatically activated. NOTE: The operator can select various retarding levels by pressing a HIGH/MEDIUM/LOW switch depending on the retarding performance required. Activation occurs through the following steps: 1. Engine oil pressure fills the housing passages up to the solenoid.

2. Activation of the engine brake is communicated by the ECM using the J1939 data link. When activated, the energized solenoid valve permits engine lube oil to flow under pressure through the control valve to both the master piston and slave piston circuits. 3. Oil pressure causes the master piston roller assembly to move down, picking up the motion of the cam (dedicated braking lobe) pushing the piston back into the housing creating high pressure oil. 4. The high pressure oil flows back through the master piston, slave piston and control valve circuits. 5. The check ball in the control valve seats, trapping oil in the circuit creating a high pressure link between the slave piston and master piston. 6. Once the high pressure link is created, the master piston follows the cam profile causing the slave piston to move down, momentarily opening exhaust valve (single valve opening), while the engine piston is near its top dead center position, releasing compressed cylinder air to the exhaust manifold. 7. Compressed air escapes to atmosphere completing compression braking cycle. NOTE: 1. The MaxxForce® Engine Brake by Jacobs® will disengage during Anti-lock Brake System (ABS) braking. 2. Will interact with the vehicle cruise control for smooth operation during engine braking 3. Will interact with the UltraShift™ Transmission for smooth up-shifts under fueling conditions


ENGINE SYSTEMS

Electronic Control System Electronic Control System Components MaxxForce® 11 and 13 engines are equipped with one control module; the Engine Control Module (ECM).

Operation and Function The ECM monitors and controls engine operation to ensure maximum performance and adherence to emissions standards. The ECM, performs the following functions:

45

and command the necessary outputs for correct performance of the engine.

Diagnostic Trouble Codes Diagnostic Trouble Codes (DTCs) are stored by the ECM if inputs or conditions do not comply with expected values. Diagnostic codes for the 2010 MY are communicated using the Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI) identifiers, and are accessed using an electronic service tool with ServiceMaxx® diagnostic software or a generic scan tool as well.

•

Provide reference voltage (VREF)

•

Condition input signals

Microprocessor Memory

•

Process and store control strategies

•

Control actuators

The ECM microprocessor includes Read Only Memory (ROM) and Random Access Memory (RAM). ROM

Reference Voltage (VREF) The ECM supplies 5 volt VREF signals to various input sensors in the electronic control system. By comparing the 5 volt VREF signal sent to the sensors with their respective returned signals, the ECM determines pressures, positions, and other variables important to engine and vehicle functions.

Signal Conditioner Signal conditioning circuitry in the ECM converts analog signals to digital signals, squares up sine wave signals, and amplifies low intensity signals.

Microprocessor The microprocessor, located inside the ECM, processes stored operating instructions (control strategies) and value tables (calibration parameters). The microprocessor compares stored instructions and values with conditioned input values to determine the correct strategy for all engine operations.

ROM stores permanent information for calibration tables and operating strategies. Permanently stored information cannot be changed or lost when the ignition switch is turned to OFF or when power to the control modules is interrupted. ROM includes the following: •

Vehicle configuration, modes of operation, and options

•

Engine Family Rating Code (EFRC)

•

Engine warning and protection modes

RAM RAM stores temporary information for current engine conditions. Temporary information in RAM is lost when the ignition switch is turned to OFF or power to control module is interrupted. RAM information includes the following: •

Engine temperature

•

Engine rpm

•

Accelerator pedal position

Diagnostic strategies are also programmed into the ECM. Some strategies monitor inputs continuously


ENGINE SYSTEMS

46 Actuator Control

Exhaust Back Pressure Valve (EBPV) Control

The ECM controls the actuators by applying a low level signal (low side driver) or a high level signal (high side driver). When switched on, both drivers complete a ground or power circuit to an actuator.

The EBPV is controlled using the ACV assembly. The ACV assembly contains the EBPV control valve, and the TC1TOP sensor. Both are used by the ECM to control EBPV operation.

Actuators are controlled in one of the following ways, depending upon type of actuator:

The EBPV regulates the amount of air pressure applied to the EBPV pneumatic actuator. The pneumatic cylinder actuates the valve (in the exhaust system) in response to commands by the ECM.

•

Duty cycle (percent time on/off)

•

PWM

•

Switched on or off

The EBPV actuator is mounted on a bracket, on the right side of the engine, after the turbocharger exhaust connection.

Actuators The ECM controls engine operation with the following:

Exhaust Gas Recirculation (EGR) Valve

•

CCV

•

EBPV

•

EGRV

•

ACV

The EGRV is mounted on the rear of the EGR cooler, on top of the engine. The EGRV assembly receives the desired valve position from the ECM. The EGRV regulates the flow of exhaust gases through the EGR system.

•

CSR

•

Cold Start Solenoid (CSS) valve

•

ETV

•

FPCV

•

AFTFD

•

AFTSV

•

CSFI relay

Air Control Valve (ACV) The ACV contains solenoids used for the control of the HP turbocharger wastegate, LP turbocharger wastegate, and EBPV. It also contains the TC1TOP sensor. ACV solenoids are controlled through pulse width modulated signals sent by the ECM. The ACV is located on the right side of the engine, mounted near the center of the EGR cooler.

Coolant Control Valve (CCV) The CMV and CFV are a combined solenoid assembly that regulates coolant flow and temperature through the LPCAC and the low temp EGR cooler. The CMV and CFV are housed in the CCV assembly. CFV controls the rate of coolant flow through the CAC, and the CMV regulates the temperature of the coolant, by directing the coolant either through the LTR or through an internal bypass. Both valves are controlled by the ECM. The CCV is installed on the water distribution housing.

Cold Start Relay (CSR) The cold start assist system aids cold engine starting by warming the incoming air supply prior to, and during, cranking, and also up to four minutes for cold engine warm-up. The ECM is programmed to energize the CSFI heater element through the CSR while monitoring certain programmed conditions for engine coolant temperature, air inlet temperature, engine oil temperature, and atmospheric pressure.


ENGINE SYSTEMS

47

The CSR delivers battery voltage (VBAT) to the heater element for a set time, depending on engine coolant temperature and altitude. The ground circuit is supplied directly from the battery ground at all times. The relay is controlled by switching on a voltage source from the ECM, and is installed to the rear of the ECM.

Aftertreatment Fuel Doser (AFTFD)

Cold Start Solenoid (CSS) Valve

Aftertreatment Shutoff Valve (AFTSV)

The CSS valve controls fuel flow to the CSFI during cold start assist operation.

The CSS valve is mounted on the intake throttle duct, on the top left side of the engine.

The AFTSV is used to prevent fuel flow to the aftertreatment fuel injector (AFI), and prevents all uncontrolled fuel delivery for the aftertreatment system during a AFTFD valve malfunction. The AFTSV is controlled through an on-off signal sent by the ECM. The AFTSV is housed in the DSI unit, which is located to the rear of the fuel filter assembly.

Engine Throttle Valve (ETV)

Engine and Vehicle Sensors

The ETV controls the flow of fresh air (boosted and cooled) into the engine’s air intake path through the CAC to help heat the exhaust aftertreatment during regeneration, and to assist when heavy EGR is requested. The electronic portion of the ETV contains a microprocessor that monitors valve position, electronic chamber temperature, controls the electric motor, and reports diagnostic faults to the ECM. The ETV changes position in response to ECM signals.

Thermistor Sensors

When cold start assist is required, the ECM provides voltage to open the CSS valve during cranking.

The AFTFD is used to provide HP fuel flow to the aftertreatment fuel injector. The AFTFD is controlled through an PWM signal sent by the ECM. The AFTFD is housed in the DSI unit, which is located to the rear of the fuel filter assembly.

The ETV is integrated into the intake throttle duct, on the top left side of the engine. Fuel Pressure Control Valve (FPCV) The FPCV is a variable position actuator that controls the flow of fuel to the suction side of the high pressure pump. The FPCV changes valve position through pulse width modulated signals from the ECM. The FPCV is mounted on the upper side of the high pressure pump. The FPCV and fuel pump are serviced as an assembly.

Figure 26

Thermistor

A thermistor sensor changes electrical resistance with changes in temperature. As temperature changes at the thermistor, voltage at the ECM will change accordingly. Thermistors work with the control module to produce a voltage signal directly proportional to temperature values.


ENGINE SYSTEMS

48

A thermistor sensor has two electrical connectors, signal return and ground. The output of a thermistor sensor is a non-linear analog signal. Thermistor type sensors include the following: •

Aftertreatment temperature sensors

•

Engine Coolant Temp sensors

•

EOT sensor

•

TC2CIS

•

CACOT sensor

•

IMT sensor

•

EGRT

•

Ambient Air Temperature (AAT) sensor

Engine Coolant Temperature (ECT) Sensors The ECT1 and ECT2 sensors are thermistor-type sensors that detect engine coolant temperature. The ECT1 signal is monitored by the ECM for operation of the instrument panel temperature gauge, coolant temperature compensation, charge air temperature control, EGR system control, optional Engine Warning Protection System (EWPS), and the wait to start lamp. The ECM uses ECT1 sensor input as a backup, if EOT sensor values are out of range. The ECT1 sensor is installed in the underside of the EGR coolant crossover manifold, at the back of the engine. The ECT2 sensor is installed in the low temperature stage of the EGR cooler, on the right side of the engine.

Aftertreatment Temperature Sensors

Engine Oil Temperature (EOT) Sensor

Four sensors used in the Aftertreatment System include the following:

The EOT sensor is a thermistor sensor that detects engine oil temperature. The EOT sensor is installed in the side oil module flange, behind the oil filter cover, on the right side of the engine.

•

Aftertreatment Fuel Inlet (AFTFI) sensor

•

DOCIT

•

DOCOT

•

DPFOT

The AFTFI sensor provides a feedback signal to the ECM indicating temperature of the fuel supplied to the downstream Injection DSI unit. The AFTFI is a dual function sensor, and also provides inlet fuel pressure values for DSI unit. The AFTFI sensor is installed in the DSI unit. The DOCIT sensor provides a feedback signal to the ECM indicating DOC inlet temperature. The DOCIT sensor is the first temperature sensor installed past the turbocharger and just before the main DOC. The DOCOT sensor provides a feedback signal to the ECM indicating DOC outlet temperature. The DOCOT sensor is the second temperature sensor installed past the turbocharger and just after the main DOC.

Turbocharger 2 Compressor Inlet Sensor (TC2CIS) The TC2CIS sensor includes a thermistor sensor that monitors the temperature of charge air entering the HP turbocharger. This sensor also monitors boost pressure for the LP turbocharger. The TC2CIS sensor is monitored by the ECM, and is used for calculating fuel delivery and controlling LP wastegate operation. The TC2CIS is installed in the piping between the LP compressor outlet and the HP compressor inlet. Charge Air Cooler Outlet Temp (CACOT) Sensor The CACOT sensor is a thermistor sensor that monitors the temperature of charge air entering the intake air duct. The CACOT signal is monitored by the ECM.

The DPFOT sensor provides a feedback signal to the ECM indicating DPF outlet temperature. The DPFOT sensor is the third temperature sensor installed past the turbocharger and just after the DPF.

The CACOT sensor is installed on the intake air duct, before the ETV.

During a catalyst regeneration, the ECM monitors all three temperature sensors.

The IMT sensor is a thermistor sensor that monitors temperature.

Intake Manifold Temperature (IMT) Sensor


ENGINE SYSTEMS

49

The IMT sensor is installed in the intake side of the cylinder head, on the left side of the engine.

Variable capacitance sensors include the following: •

DPFDP sensor

Exhaust Gas Recirculation Temperature (EGRT) Sensor

•

EFP sensor

•

EOP sensor

•

FRP sensor

•

IMP sensor

•

AFTFI sensor

•

AFTFP2 sensor

Ambient Air Temperature (AAT) Sensor

•

TC1TOP

The AAT sensor is a thermistor sensor that detects the temperature of ambient.

DPF Differential Pressure (DPFDP) Sensor

The EGRT sensor is a thermistor sensor that detects the exhaust gas temperature entering the EGR cooler. The EGRT signal is monitored by the ECM. The EGRT sensor is installed in the front of the low temp EGR cooler on the left side.

The AAT signal is monitored by the ECM. The AAT sensor is installed in various places on the vehicle.

The DPFDP sensor provides a feedback signal to the ECM indicating the pressure difference between the inlet and outlet of the particulate filter. The DPFDP sensor is a differential pressure sensor with two tap-offs installed at the DPF. A tap-off is located before and after the DPF.

Variable Capacitance Sensors Engine Fuel Pressure (EFP) Sensor The EFP sensor is a variable capacitance sensor that measures fuel supply pressure. The EFP sensor provides feedback to the ECM for the LP fuel system. The EFP sensor is installed in the front of the fuel filter assembly on the left side of the engine. Engine Oil Pressure (EOP) Sensor The EOP sensor is a variable capacitance sensor that detects engine oil pressure. Figure 27

Variable capacitance sensor example

Variable capacitance sensors measure pressure. The pressure measured is applied to a ceramic material. The pressure forces the ceramic material closer to a thin metal disk. This action changes the capacitance of the sensor. The sensor is connected to the control module through the VREF, signal, and signal ground wires. The sensor receives the VREF and returns an analog signal voltage to the ECM. The ECM compares the voltage with pre-programmed values to determine pressure.

The EOP signal is monitored by the ECM for operation of the instrument panel pressure gauge and optional EWPS. The EOP sensor is installed in the oil module, on the right side of the engine. Fuel Rail Pressure (FRP) Sensor The FRP sensor is a variable capacitance sensor that monitors fuel pressure in the HP fuel rail. The FRP sensor measures fuel pressure just before injection. The FRP sensor is mounted in the front of the fuel rail on the left side of the engine.


ENGINE SYSTEMS

50 Intake Manifold Pressure (IMP) Sensor

Magnetic Pickup Sensors

The IMP sensor is a variable capacitance sensor that monitors the pressure of charge air entering the intake air duct. The IMP signal is monitored by the ECM for control of the EGR system and turbocharger wastegates. The IMP sensor is installed on the intake air duct, after the ETV. Aftertreatment Fuel Inlet (AFTFI) Sensor The AFTFI sensor is a dual function sensor and includes a thermistor sensor that monitors inlet fuel Temperature for the DSI unit. The AFTFI sensor includes a variable capacitance sensor that measures fuel pressure supplied by the DSI unit, and is used to monitor fuel delivery to the aftertreatment system.

Figure 28

Magnetic pickup sensor example

The AFTFI sensor is located in the DSI unit, to the rear of the fuel filter assembly. Aftertreatment Fuel Pressure 2 (AFP2) sensor The AFTFP2 sensor is a variable capacitance sensor that monitors fuel pressure after the Aftertreatment Shutoff Valve (ASV).

A magnetic pickup sensor contains a permanent magnet core that is surrounded by a coil of wire. The sensor generates a voltage signal through the collapse of a magnetic field created by a moving metal trigger. The movement of the trigger then creates Alternate Current (AC) voltage in the sensor coil.

The AFP2 sensor measures fuel pressure supplied by the ASV to the AFTFD valve, and is used to monitor fuel delivery to the aftertreatment system.

Magnetic pickup sensors used include the following: •

CKP sensor

The AFP2 sensor is located in the DSI unit, to the rear of the fuel filter assembly.

•

CMP sensor

•

VSS

Turbocharger 1 Turbine Outlet Pressure (TC1TOP)

•

CCOSS sensor

The TC1TOP sensor is a variable capacitance sensor that monitors exhaust back pressure.

Crankshaft Position (CKP) Sensor

The sensor measures back pressure in the exhaust system. A tap for the TC1TOP is located in the exhaust, between the LP turbocharger and EBPV. The TC1TOP sensor is located in the Air Control Valve, on the right side of the engine.

The CKP sensor is a magnetic pickup sensor that indicates crankshaft speed and position. The CKP sensor sends a pulsed signal to the Engine Control Module (ECM) as the crankshaft turns. The CKP sensor reacts to holes drilled into the flywheel adjacent to the ring gear. For crankshaft position reference, teeth 59 and 60 are missing. By comparing the CKP signal with the CMP signal, the ECM calculates engine rpm and timing requirements. The CKP sensor is installed in the top left of the flywheel housing.


ENGINE SYSTEMS Camshaft Position (CMP) Sensor

51

Potentiometer Sensors

The CMP sensor is a magnetic pickup sensor that indicates camshaft speed and position. The CMP sensor sends a pulsed signal to the ECM as a toothed wheel on the camshaft rotates past the CMP sensor. The ECM calculates camshaft speed and position from CMP signal frequency. The CMP sensor is installed in the left rear of the cylinder head. Vehicle Speed Sensor (VSS) The VSS provides the ECM with transmission tail shaft speed by sensing the rotation of a 16-tooth gear on the rear of the transmission. The detected sine wave signal (AC) received by the ECM, is used with tire size and axle ratio to calculate vehicle speed. The VSS is located on the left side of the transmission housing for automatic transmissions, or at rear of the transmission housing for manual transmissions. Crankcase Oil Separator Speed (CCOSS) sensor The CCOSS sensor sends the ECM information about the speed of the crankcase oil separator internal components. The detected sine wave signal (AC) received by the ECM is used to monitor proper operation of the cyclonic oil separator, located inside the breather assembly on the engine oil filter assembly.

Figure 29

Potentiometer example

A potentiometer is a variable voltage divider that senses the position of a mechanical component. A reference voltage is applied to one end of the potentiometer. Mechanical rotary or linear motion moves the wiper along the resistance material, changing voltage at each point along the resistive material. Voltage is proportional to the amount of mechanical movement. The engine has two potentiometers, both contained in the Accelerator Pedal Position (APP) Sensor. Accelerator Pedal Position (APP) The APP provides the ECM with a dual feedback signal (dual linear analog voltages) that indicate the operator’s demand for power. The APP contains two potentiometers, and provides two individual signals (APP and APP2) to the ECM. The APP is installed in the cab on the accelerator pedal assembly.


ENGINE SYSTEMS

52

Engine Coolant Level (ECL) Switch

Switches

The ECL switch is part of the EWPS. The ECL switch is located on the deaeration tank. When the magnetic switch is open, the tank is considered full of coolant. If engine coolant is low, the switch closes and the red ENGINE lamp on the instrument panel is illuminated. Oil Level Sensor (OLS) The OLS is part of the EWPS. The OLS is located on the engine oil pan. The OLS measures the volume of oil in the oil pan and broadcast the percentage volume over J1939 CAN. If the level of engine lube oil is low, the red ENGINE lamp on the instrument panel is illuminated.

Additional Sensors Oxygen Sensor (O2S) Figure 30

Switch example

Switch sensors indicate position, level, or status. They operate open or closed, regulating the flow of current. A switch sensor can be a voltage input switch or a grounding switch. A voltage input switch supplies the control module with a voltage when it is closed. A grounding switch grounds the circuit when closed, causing a zero voltage signal. Grounding switches are usually installed in series with a current limiting resistor. Switches include the following: •

Driveline Disengagement Switch (DDS)

•

Engine Coolant Level (ECL)

•

Oil Level Sensor (OLS)

Driveline Disengagement Switch (DDS) The DDS determines if a vehicle is in gear. For manual transmissions, the clutch switch serves as the DDS. For automatic transmissions, the neutral indicator switch functions as the DDS. The DDS signal is sent to the Body Controller (BC) and transmitted on the J1939 datalink to the engine ECM.

The O2S monitors oxygen levels in the exhaust. The O2S is used to control the EGR flow to a specified air-to-fuel ratio by monitoring the level of unused oxygen in the exhaust stream. The O2S compares oxygen levels in the exhaust stream with oxygen levels in the outside air. The sensor generates an analog voltage and is monitored by the ECM. The level of voltage generated by the O2S directly corresponds to the oxygen levels in the exhaust stream. The O2S is installed in the turbocharger exhaust pipe, directly after the EBPV.

Humidity Sensor (HS) The HS measures the moisture content of filtered air entering the intake system. Using the HS, the ECM will adjust in order to prevent condensation of airborne water particles (moisture). The HS also houses the AIT sensor, which is used by the ECM for calculating fuel delivery.


MOUNTING ENGINE ON STAND

53

Table of Contents

Mounting Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Engine Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58


54




Mounting Engine

55

Mounting Engine on Stand NOTE: Before mounting engine on engine stand, complete the following steps.

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminated materials according to applicable regulations.

1. Drain any remaining coolant from individual components as necessary into a suitable container.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual.

5. Tighten oil drain plug to special torque (page 58).

2. Remove oil drain plug and drain oil into a suitable container. 3. Inspect oil drain plug O-ring. Discard and replace if damaged. 4. After oil is drained, lubricate oil drain plug O-ring with clean engine oil and install oil drain plug.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING: To prevent personal injury or death, make sure the engine is supported before removing mounting hardware. Engine Cleaning 1. Using Disposable Air and Fuel Caps (page 58), cover all engine openings to prevent water, degreasing agents or detergents from entering engine. 2. Cover exposed electrical connectors and the Engine Control Module (ECM) using plastic and duct tape. 3. Use an appropriate detergent mixed in the correct ratio as described on the detergent directions and apply to engine using a hot pressure washer or similar cleaning equipment.

Figure 31 Low-pressure charge air cooler (LPCAC) and tubes 1. 2. 3. 4.

Open breather tube assembly Heater hose return tube HCI coolant return tube assembly LPCAC

6. Remove HCI coolant return tube assembly. See “TURBOCHARGERS” for procedure. 7. Disconnect heater hose return tube from water distribution housing, tube clamp and open breather tube assembly. See “TURBOCHARGERS” for procedure.



56

8. Remove open breather tube assembly. “TURBOCHARGERS” for procedure.

See

9. Remove Low-Pressure Charge Air Cooler (LPCAC). See “TURBOCHARGERS” for procedure.

10. Remove four M14 x 50 bolts and engine front mount support (right). 11. Remove starter motor assembly. WARNING: To prevent personal injury or death, use a chain hoist rated for the weight of the engine, follow manufacturer’s installation and safety instructions, and attach safety latch lifting hooks to lifting eyes on the engine. 12. Attach hoist hook lifting bracket to engine lifting eyes. Use safety catches on hoist hooks when lifting engine.

Figure 32 side) 1. 2.

Engine front mount support (right

M14 x 50 bolt (4) Engine front mount support

NOTE: For reinstallation of engine front mount support, tighten M14 x 50 bolts to special torque (page 58).

Figure 33 Engine Stand Adapter Plate (mounting bracket)



WARNING: To prevent personal injury or death, use metric class 10.9 or SAE grade 8 bolts when mounting Engine Stand Adapter Plate to engine and engine stand. See instructions included with engine stand and Engine Stand Adapter Plate. NOTE: See manufacturer’s safety instructions included with engine stand and Engine Stand Adapter Plate.

13. Position Engine Stand Adapter Plate (page 58) on right side of engine. Secure adapter plate with six mounting bolts and washers (part of Engine Stand Adapter Plate). Tighten bolts to standard torque (page 471). 14. Mount engine on engine stand using four 5/8 x 1.5 inch grade 8 mounting bolts. Tighten bolts to standard torque (page 471) .

Figure 34 Engine Stand Adapter Plate (mounting bracket) 1. 2.

57

Hex bolt (part of ZTSE4789) Engine Stand Adapter Plate (mounting bracket)



58 Special Torque Table 1

Mounting Engine on Stand

M14 x 50 engine front mount support bolts Oil drain plug

225 N·m (166 lbf·ft) 75 N·m (55 lbf·ft)

Special Service Tools Table 2


Description

Tool Number

Disposable Air and Fuel Caps

ZTSE4891

Engine Stand Adapter Plate

ZTSE4789


ENGINE ELECTRICAL

59

Table of Contents

Electronic Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Description of Engine Sensors, Valves and Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Engine Coolant Temperature (ECT) Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Mass Air Flow (MAF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Humidity / Air Inlet Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Charge Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Rail Fuel Pressure (RFP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Air Control Valve (ACV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Mass Air Flow (MAF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Humidity / Intake Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Rail Fuel Pressure (RFP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

60

ENGINE ELECTRICAL Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Wiring Harness ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Engine Injector (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Engine Sensor (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Engine Control Module (ECM) and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Engine Injection and Engine Sensor Wiring Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Sensors and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Engine Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Engine Control Module (ECM) and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Engine Sensor (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Engine Injector (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Wiring Harness ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Rail Fuel Pressure (RFP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Humidity / Air Inlet Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Mass Air Flow (MAF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106


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61

Electronic Component Location

Figure 35 1. 2. 3. 4. 5.

Electronic components – right front

Humidity / Air Inlet Temperature (IAT) sensor Mass Air Flow (MAF) sensor Air Control Valve (ACV) assembly Engine Coolant Temperature 2 (ECT2) sensor Crankcase Oil Separator Speed (CCOSS) sensor

6. 7.

8. 9.

Exhaust Gas Recirculation Temperature (EGRT) sensor Engine Oil Temperature (EOT) sensor (behind CCV in oil module flange) Coolant Control Valve (CCV) assembly Engine Oil Pressure (EOP) sensor

10. Turbocharger 2 Compressor Inlet Sensor (TC2CIS) 11. Oxygen Sensor (O2S) (in exhaust back pressure valve housing)


ENGINE ELECTRICAL

62

Figure 36 1. 2. 3. 4. 5.

Electronic components – left rear

Charger Air Cooler Outlet Temperature (CACOT) sensor Intake Manifold Pressure (IMP) sensor Engine Control Module (ECM) Intake Manifold Temperature (IMT) sensor Exhaust Gas Recirculation (EGR) valve

6. 7.

Camshaft Position (CMP) sensor Engine Coolant Temperature (ECT1) sensor 8. Oxygen Sensor (O2S) connector 9. Crankshaft Position (CKP) sensor 10. Engine Oil Level (EOL) sensor 11. Fuel Delivery Pressure (FDP) sensor

12. Fuel Pressure Control Valve (FPCV) (at back of high-pressure fuel pump) 13. Rail Fuel Pressure (RFP) sensor (behind ECM, at front of fuel rail) 14. Engine Throttle Valve (ETV)


ENGINE ELECTRICAL

Description of Engine Sensors, Valves and Actuators

63

Camshaft Position (CMP) Sensor

NOTE: Refer to the following publications for information on diagnostics and troubleshooting: •

EGES-470 MaxxForce® 11 and 13 Engine Diagnostic Form

•

EGED-475 MaxxForce® 11 and 13 Engine Diagnostic Form

•

EGED-500 MaxxForce® 11 and 13 Electronic Control System Diagnostic Form


Figure 38

CMP sensor

The CMP sensor is a magnetic pickup sensor that indicates camshaft speed and position. The CMP sensor sends a pulsed signal to the ECM as a toothed wheel on the camshaft rotates past the CMP sensor. The ECM calculates camshaft speed and position from CMP signal frequency. The CMP sensor is installed in the left rear of the cylinder head. Figure 37

CKP sensor Engine Coolant Temperature (ECT) Sensors

The CKP sensor is a magnetic pickup sensor that indicates crankshaft speed and position. The CKP sensor sends a pulsed signal to the Engine Control Module (ECM) as the crankshaft turns. The CKP sensor reacts to holes drilled into the flywheel adjacent to the ring gear. For crankshaft position reference, teeth 59 and 60 are missing. By comparing the CKP signal with the Camshaft Position (CMP) signal, the ECM calculates engine rpm and timing requirements. The CKP sensor is installed in the top left of the flywheel housing.

Figure 39

ECT sensor


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64

The ECT1 and ECT2 sensors are thermistor sensors that detect engine coolant temperature.

Engine Oil Pressure (EOP) Sensor

The ECT1 and ECT2 signals are monitored by the ECM for operation of the instrument panel temperature gauge, coolant temperature compensation, charge air temperature control, Exhaust Gas Recirculation (EGR) system control, optional Engine Warning Protection System (EWPS) and the wait to start lamp. The ECM uses ECT1 sensor input as a backup, if Engine Oil Temperature (EOT) sensor values are out of range. The ECT1 sensor is installed in the underside of the EGR coolant crossover manifold at the back of the engine. The ECT2 sensor is installed in the low-temperature stage of the EGR cooler on the right side of the engine. Figure 41

EOP sensor

Engine Oil Temperature (EOT) Sensor The EOP sensor is a variable resistance sensor that detects engine oil pressure. The EOP signal is monitored by the ECM for operation of the instrument panel pressure gauge and optional EWPS. The EOP sensor is installed in the oil module, on the right side of the engine. Crankcase Oil Separator Speed (CCOSS) Sensor

Figure 40

EOT sensor

The EOT sensor is a thermistor sensor that detects engine oil temperature, and is monitored by the ECM for cold start assist. The EOT sensor is installed in the oil module flange, behind the CCV on the right side of the engine. Figure 42

CCOSS sensor

The CCOSS sensor sends the ECM information about the speed of the crankcase oil separator internal components. The detected sine wave signal (AC) is used to monitor proper operation of the cyclonic EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

ENGINE ELECTRICAL

65

oil separator, located on the oil centrifuge on the oil module assembly.

The FPCV is a variable-position actuator that controls the flow of fuel to the suction side of the high-pressure fuel pump.

Fuel Delivery Pressure (FDP) Sensor

The FPCV changes valve position through pulse-width modulated signals from the ECM. The FPCV is mounted on the upper side of the high-pressure fuel pump. The FPCV and high-pressure fuel pump are serviced as an assembly.

Mass Air Flow (MAF) Sensor

Figure 43

FDP sensor

The FDP sensor is a variable resistance sensor that measures fuel supply pressure, and provides feedback to the ECM for the low pressure fuel system. The FDP sensor is installed in the front of the fuel filter housing assembly on the left side of the engine.

Fuel Pressure Control Valve (FPCV)

Figure 45

MAF sensor

The MAF sensor measures the amount of filtered air entering the engine intake system. The MAF sensor provides a digital signal to the ECM and will vary frequency depending on the amount of air entering the intake. The MAF sensor is installed in the air inlet duct, before the low-pressure turbocharger compressor inlet.

Figure 44

FPCV EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

ENGINE ELECTRICAL

66

Humidity / Air Inlet Temperature (IAT) Sensor

The CACOT sensor is a thermistor sensor that monitors the temperature of charge air entering the intake air duct. The CACOT signal is monitored by the ECM for control of the EGR system. The CACOT sensor is installed on the air intake throttle duct, before the Engine Throttle Valve (ETV).

Intake Manifold Pressure (IMP) Sensor

Figure 46

IAT

The IAT measures the moisture content of filtered air entering the intake system. The IAT is used by the ECM to prevent EGR system component degradation due to moisture contamination. Using the sensor, the ECM will adjust EGR system flow to prevent condensation of airborne water particles. The sensor also measures intake air temperature, which is used by the ECM for calculating fuel delivery.

Figure 48

IMP sensor

The IAT is mounted in the air inlet duct at the upper right side of the engine.

The IMP sensor is a variable capacitance sensor that monitors the pressure of charge air entering the air intake throttle duct. The IMP signal is monitored by the ECM for control of the EGR system and turbocharger wastegates.

Charge Air Cooler Outlet Temperature (CACOT) Sensor

The IMP sensor is installed on the air intake throttle duct after the ETV.

Figure 47

CACOT sensor EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

ENGINE ELECTRICAL Rail Fuel Pressure (RFP) Sensor

67

The IMT sensor is a thermistor sensor that monitors the temperature of the mixture of recirculated exhaust gas and fresh intake air. EGR system operation is shut down under certain temperature conditions, to prevent acids from condensing under cold charge-air temperatures and to protect the engine from excessively hot intake air in the event of an EGR fault. The IMT sensor is installed in the intake channel of the cylinder head, on the left side of the engine.

Oxygen Sensor (O2S)

Figure 49

RFP sensor

The RFP sensor is a variable capacitance sensor that monitors the fuel pressure in the high-pressure fuel rail. The sensor measures the fuel pressure just before injection. The RFP sensor is mounted in the front of the fuel rail on the left side of the engine.

Intake Manifold Temperature (IMT) Sensor Figure 51

O2S

The O2S monitors oxygen levels in exhaust gases. It is used to tune engine operation by monitoring the level of unused oxygen in the exhaust stream. The O2S compares oxygen levels in the exhaust stream with oxygen levels in the outside air. The sensor generates an analog voltage and is monitored by the ECM. The level of voltage generated by the O2S corresponds to the oxygen levels in the exhaust stream. The O2S is installed in the exhaust back pressure valve housing. Figure 50

IMT sensor


ENGINE ELECTRICAL

68 Engine Throttle Valve (ETV)

Coolant Control Valve (CCV)

Figure 52

Figure 53

ETV

The ETV controls the flow of filtered air (boosted and cooled) into the engine’s air intake through the Charge Air Cooler (CAC) to help heat the exhaust aftertreatment during regeneration, and to assist when heavy EGR is requested. The electronic portion of the ETV contains a microprocessor that monitors valve position, electronic chamber temperature, controls the electric motor and reports diagnostic faults to the ECM. The ETV changes position in response to ECM signals. The ETV is integrated into the air intake throttle duct at the front top left side of the engine.

CCV

The Coolant Mixer Valve (CMV) and Coolant Flow Valve (CFV) are a combined solenoid assembly that regulates coolant flow and temperature through the Low-Pressure Charge Air Cooler (LPCAC) and the low temperature EGR cooler. The CMV and CFV are housed in the CCV assembly. The CFV controls the rate of coolant flow through the CAC and the CMV regulates the temperature of the coolant by directing the coolant either through the low temperature radiator or through an internal bypass. Both valves are controlled by the ECM. The CCV is mounted on the right side of the water distribution housing.


ENGINE ELECTRICAL Air Control Valve (ACV) Assembly

69

The EGR valve regulates the flow of exhaust gases through the EGR system. The desired valve position is controlled by commands from the ECM. The EGR valve is mounted on the rear of the EGR cooler on top of the engine.


Figure 54

ACV

The ACV contains solenoids used for the control of the high-pressure turbocharger wastegate, low-pressure turbocharger wastegate and Exhaust Back Pressure Valve (EBPV). It also contains the Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor. ACV solenoids are controlled through pulse-width modulated signals sent by the ECM. The ACV assembly is installed on the right side of the engine, mounted near the center of the EGR cooler.


Figure 56

EGRT sensor

The EGRT sensor is a thermistor sensor that detects the exhaust gas temperature exiting the EGR cooler. The sensor signal is monitored by the ECM to control the Coolant Flow Valve (CFV) and Coolant Mixer Valve (CMV), and check for proper EGR cooling. The EGRT sensor is installed in the front of the low-temperature EGR cooler on the left side.

Figure 55

EGR valve


ENGINE ELECTRICAL

70

Turbocharger 2 Compressor Inlet Sensor (TC2CIS)

The TC2CIS sensor includes a thermistor sensor that monitors the temperature of charge air entering the high-pressure turbocharger. This sensor also monitors boost pressure for the low-pressure turbocharger. The TC2CIS sensor is monitored by the ECM, and is used to check for proper thermostat operation and charge air cooling. The TC2CIS is installed in the piping between the low-pressure compressor outlet and the high-pressure compressor inlet.

Figure 57

TC2CIS


ENGINE ELECTRICAL

Removal GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminated materials according to applicable regulations.

71

Disconnect ground cable (–) from the negative terminal of the battery. Crankshaft Position (CKP) Sensor

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, remove ground cable from negative terminal of main battery before disconnecting or connecting electrical components. Always connect ground cable last. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and free connectors or clips.

Figure 58 1. 2. 3. 4.

CKP sensor (typical)

Locking tab M6 x 16 bolt CKP sensor CKP harness connector

1. Pull out yellow locking tab on CKP sensor harness connector. 2. Press release lever and disconnect harness connector from CKP sensor installed in top left of flywheel housing. 3. Remove M6 x 16 bolt from CKP sensor. 4. Remove CKP sensor and discard O-ring.


ENGINE ELECTRICAL

72 Camshaft Position (CMP) Sensor

Figure 59

Engine Coolant Temperature 1 (ECT1) Sensor

CMP sensor (typical) Figure 60

1. Pull out yellow locking tab on CMP sensor harness connector. 2. Press release lever and disconnect harness connector from CMP sensor installed in rear left of cylinder head. 3. Remove M6 x 12 bolt from CMP sensor. 4. Remove CMP sensor and discard O-ring.

ECT1 sensor

1. Turn ECT1 sensor harness connector locking ring 90° counterclockwise. 2. Disconnect harness connector from ECT1 sensor installed in underside of Exhaust Gas Recirculation (EGR) coolant manifold at rear of engine. 3. Remove ECT1 sensor and discard seal ring.


ENGINE ELECTRICAL

73



Figure 61

Figure 62

ECT2 sensor connector

1. Turn ECT2 sensor harness connector locking ring 90°counterclockwise. 2. Disconnect harness connector from ECT2 sensor installed in EGR module low-temperature housing on upper right side of engine. 3. Remove ECT2 sensor and discard seal ring.

1. 2.

EOT sensor

EOT sensor Oil module flange

1. Turn EOT harness connector locking ring 90° counterclockwise. 2. Disconnect harness connector from EOT sensor and remove sensor from oil module flange. Discard seal ring.


ENGINE ELECTRICAL

74 Engine Oil Pressure (EOP) Sensor

Figure 63 1. 2.

EOP sensor

Oil module assembly EOP sensor

Crankcase Oil Separator Speed (CCOSS) Sensor

Figure 64 1. 2. 3.

CCOSS sensor

CCOSS sensor Oil centrifuge (part of oil module assembly) M6 x 14 bolt and nut

1. Turn EOP harness connector locking ring 90° counterclockwise. 2. Disconnect harness connector from EOP sensor and remove sensor from oil module assembly. Discard seal ring.

1. Press release tab to disconnect wiring harness connector from CCOSS sensor. 2. Remove M6 x 14 bolt and nut and remove sensor from bracket on oil centrifuge.


ENGINE ELECTRICAL Fuel Delivery Pressure (FDP) Sensor

75

1. Pull out yellow locking tab on FPCV harness connector. 2. Press release tab and disconnect harness connector from FPCV mounted at upper rear of high-pressure fuel pump. 3. See (High-pressure Fuel Pump (HPFP) and Drive Housing, page 210) for removal of high-pressure pump with integral FPCV if the FPCV requires replacement.


Figure 65

FDP sensor

1. Turn FDP sensor harness connector locking ring 90° counterclockwise. 2. Disconnect harness connector from FDP sensor installed in fuel filter assembly. 3. Remove FDP sensor and discard seal ring.

Fuel Pressure Control Valve (FPCV) Figure 67 1. 2. 3.

MAF sensor

M4 x 0.7 cap screw (2) MAF sensor Harness connector

1. Pull out yellow tab to release wiring harness connector from MAF sensor. 2. Remove two M4 x 0.7 cap screws and remove sensor from air inlet duct. 3. Discard O-ring.

Figure 66 1. 2.

FPCV (on high-pressure fuel pump)

FPCV Harness connector


ENGINE ELECTRICAL

76

Humidity / Intake Air Temperature (IAT) Sensor

Figure 68 1. 2. 3.

IAT

Figure 69

M6 x 16 bolt (2) Harness connector IAT

1. 2. 3.

1. Pull out yellow locking tab on IAT harness connector. 2. Press release tab to disconnect connector from IAT sensor.

Charger Air Cooler Outlet Temperature (CACOT) Sensor

harness

3. Remove two M6 x 16 bolts and remove sensor from air inlet duct. Discard O-ring.

CACOT sensor

CACOT sensor Harness connector Standoff tie strap

1. Press release tab to loosen tie strap and remove standoff bracket securing connector harness lead to CACOT sensor. 2. Press release tab to disconnect harness from CACOT sensor. 3. Remove CACOT sensor from throttle valve housing. Discard O-ring.


ENGINE ELECTRICAL Intake Manifold Pressure (IMP) Sensor

Rail Fuel Pressure (RFP) Sensor

Figure 71 Figure 70 1. 2. 3.

77

RFP sensor (typical)

IMP sensor

IMP sensor Standoff tie strap Harness connector

1. Press release tab to loosen tie strap and remove standoff bracket securing harness connector lead to IMP sensor. 2. Press release tab to disconnect harness from IMP sensor.

1. Pull out yellow locking tab on RFP sensor harness connector. 2. Press release lever and disconnect harness connector from RFP sensor installed in front of fuel rail on left side of engine. 3. Remove sensor from fuel rail. 4. Cover exposed fuel rail opening using Disposable Air and Fuel Caps (page 106).

3. Remove IMP sensor from ETV housing. Discard O-ring.


ENGINE ELECTRICAL

78


Figure 72

Oxygen Sensor (O2S)

IMT sensor

1. Turn IMT sensor harness connector locking ring 90° counterclockwise. 2. Disconnect harness connector from IMT sensor.

Figure 73 clarity) 1. 2. 3.

O2S (valve actuator removed for

Exhaust back pressure valve housing O2S (with harness lead) Clip (2)

3. Remove IMT sensor from cylinder head and discard seal ring. 1. Press release lever and disconnect O2S harness lead from engine electrical harness at left rear of engine. 2. Disconnect clips securing O2S harness lead at right rear of engine to coolant tube and to valve actuator bracket. NOTE: The O2S has a non-serviceable seal ring. If sensor is removed, the complete sensor must be replaced. 3. Only if required, remove O2S from exhaust back pressure valve housing and discard.


ENGINE ELECTRICAL Engine Throttle Valve (ETV)

Coolant Control Valve (CCV)

Figure 75 Figure 74 1. 2.

ETV

ETV harness connector ETV

1. Press release tab and disconnect harness connector from ETV, located on top left front of engine. 2. See (Glow Plug and Fuel Supply Cold Start Hose, page 111) for removal procedure of the fuel supply cold start hose. 3. See (Air Intake Throttle Duct, page 277) for removal procedure of duct.

79

1. 2.

CCV

Coolant Mixer Valve (CMV) terminal Coolant Flow Valve (CFV) terminal

NOTE: The coolant mixer and coolant flow valves are not serviced separately. Both valves are an integral part of the CCV assembly which is available as a unit. 1. Press release tab and disconnect harness connector from CMV, installed in the CCV assembly on the right side of the water distribution housing. 2. Lift release tab and disconnect harness connector from CFV, also in the CCV assembly. 3. See Coolant Control Valve (CCV) for removal procedure.


ENGINE ELECTRICAL

80 Air Control Valve (ACV)


Figure 76

Figure 77

1. 2.

ACV

Harness connector ACV assembly

1. Press release tab and disconnect harness connector from ACV mounted on EGR cooler assembly high-temperature housing at top right of engine. 2. Remove ACV. See (Air Control Valve , page 140) in ”EXHAUST BACK PRESSURE CONTROL” section for removal procedure.

1. 2.

EGR valve harness connector

Harness connector EGR valve

1. Press release tab to disconnect wiring harness lead from EGR valve connector. 2. Remove dual flap EGR valve. See (EGR Dual Flap Valve, page 261) in “EXHAUST GAS RECIRCULATION (EGR) SYSTEM” for removal procedure.


ENGINE ELECTRICAL Exhaust Gas Recirculation Temperature (EGRT) Sensor


Figure 79 1. 2.

Figure 78 1. 2.

EGRT sensor harness connector

EGR module cover EGRT sensor

TC2CIS

M6 x 16 bolt (2) TC2CIS

1. Pull out yellow lock tab on TC2CIS harness connector. 2. Press release tab and disconnect harness lead from TC2CIS.

1. Pull out red locking tab on EGRT sensor connector. 2. Press release tab to disconnect connector from EGRT sensor.

81

harness

NOTE: The EGRT has a non-serviceable crush washer for sealing. If sensor is removed, the complete sensor must be replaced. 3. Only if required, remove EGRT sensor from EGR module cover and discard.

3. Remove two M6 x 16 bolts and sensor from high-pressure turbocharger air supply duct. Discard O-ring seal.

Wiring Harness ECM Connections WARNING: To prevent personal injury or death, remove ground cable from negative terminal of main battery before disconnecting or connecting electrical components. Always connect ground cable last. CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and free connectors or clips. 1. If not done, disconnect ground (–) cable from the negative terminal of the battery. 2. Note location of wire ties for reinstallation. Cut wire ties securing engine injector, engine sensor and chassis harness connector lock levers at ECM.


ENGINE ELECTRICAL

82

Engine Injector (Wiring) Harness

Figure 80 1. 2. 3. 4. 5.

ECM harness connectors

ECM Engine injector harness connector (to ECM 16-pin E2 terminal) ECM 58-pin C2 chassis terminal ECM 58-pin C1 chassis terminal Engine sensor harness connector (to ECM 96-pin E1 terminal)

Figure 81 at ECM 1. 2.

Injector harness attachment points

Injector harness M6 x 30 bolt (2)

1. Remove two M6 x 30 bolts and remove injector harness retainer clips from ECM. 3. If not already done, disconnect chassis wiring harness connectors from ECM 58-pin C1 and C2 terminals. 4. Remove connector clip and lift lock lever to release engine injector harness connector. Pull straight out to remove connector from ECM terminal E2.

2. Remove upper valve cover from valve cover base. See (Upper Valve Cover and Base, page 341) in the “CYLINDER HEAD, CAMSHAFT, AND VALVE TRAIN” section for removal procedure.

5. Lift lock lever to release engine sensor harness connector. Pull straight out to remove connector from ECM terminal E1.


ENGINE ELECTRICAL

83

3. Loosen 12 harness nuts (two at each injector) and disconnect harness leads from injector terminals. 4. Cut tie straps at six locations securing injector harness to valve cover base. 5. Cut tie strap securing harness at center of cylinder head. 6. Remove four M6 x 16 bolts from injector harness mounting flange. 7. Carefully pull harness through valve cover base opening and remove harness from engine.

Figure 82 Injector harness attachment points at cylinder head 1. 2. 3.

Injector harness nut (12) Tie strap (7) M6 x 16 bolt (4)


ENGINE ELECTRICAL

84 Engine Sensor (Wiring) Harness

Figure 83 1.

Sensor harness attachment points, right front

Tie strap (4)

2.

M8 x 12 bolt

1. Disconnect harness connectors at IAT, MAF, TC2CIS, EOP, ACV, ECT2, CCOSS, CCV and EOT terminals. 2. Starting on right side at front, cut tie straps securing sensor harness at ACV, CCV and to air supply tube.

3.

M8 x 16 bolt (2)

4. Remove two M8 x 16 bolts attaching harness clip to EGR module cover. 5. At left front, disconnect harness connectors at EGRT, CACOT, IMP, RFP, FDP and EOL sensors.

3. Remove M8 x 12 bolt attaching harness clip to EGR cooler low-temperature housing.


ENGINE ELECTRICAL

Figure 84 1.

85

Sensor harness attachment points at left front (air intake throttle duct removed for clarity)

Tie strap (3)

2.

M6 x 16 bolt

6. Cut tie straps securing sensor harness to back of air intake throttle duct and at back and bottom of ECM support.

3.

Other attachments

8. Remove other attachments as necessary. 9. At left rear, disconnect harness connectors at CMP, CKP, ECT1 sensors and EGR valve.

7. Remove M6 x 16 bolt attaching harness clip to coolant outlet manifold.


ENGINE ELECTRICAL

86

Figure 85 1. 2.

Sensor harness attachment points at left rear

M8 x 16 bolt (2) Tie strap (3)

3. 4.

M8 stud Harness clips

5.

21-way connector

10. At left side and rear of engine, cut tie straps securing sensor harness to harness support and coolant manifold.

13. Remove sensor harness from engine using care to avoid damage to harness as it is removed from around components.

11. Disconnect harness from M8 stud at coolant manifold.

14. Remove 21-way connector from harness bracket.

12. At left center of engine, remove two M8 x 16 bolts attaching harness bracket to crankcase.


ENGINE ELECTRICAL

87

Engine Control Module (ECM) and Support


ECM mounting bolts

ECM M6 x 30 bolt (8)

1. Remove eight M6 x 30 bolts and remove ECM from support.

1. 2. 3. 4.

ECM support

Cold Start Solenoid (CSS) ECM support Cold Start Relay (CSR) M8 x 40 bolt (3) with EDC bracket insulators (6)

2. Remove CSR from ECM support. See (Relay Assembly, page 110) in “COLD START ASSIST” section to remove CSR. 3. Remove CSS from ECM support. See (Fuel Supply Solenoid Hose, page 111) in “COLD START ASSIST” section to remove CSS. 4. Remove three M8 x 40 bolts, six EDC bracket insulators (three on each side of support) and ECM support from cylinder head.


ENGINE ELECTRICAL

88

Cleaning and Inspection Engine Injection and Engine Sensor Wiring Harnesses 1. Carefully inspect engine injection wiring harnesses for worn conduit, frayed insulation or heat damage to wires. Repair or replace if necessary. 2. Inspect injector terminal ends and ECM connector for cracked connector body, loose pins, chafing and damaged or terminal nuts. Replace connector or ends if necessary. 3. Inspect each connector for the conditions and replace, if necessary:

terminal bent or missing terminal

following

•

Corroded connectors and green, gray or white deposits on metal terminals.

•

Terminals incorrectly latched in connector body or pushed back relative to other terminals in same connector.

•

Make sure that each connector has its seals in place. During disassembly, a seal may pull off its connector and remain in mating socket of a sensor or actuator. A connector assembled without the correct seals can be contaminated with moisture and have corroded terminals, causing a poor electrical connection.

4. Carefully inspect main engine sensors wiring harness for worn conduit, frayed insulation or heat damage to wires. Repair or replace if necessary. 5. Inspect sensor, actuator and valve connectors for cracked connector bodies, bent or loose

pins, chafing and damaged or missing O-rings. Replace connectors if necessary. 6. Inspect each connector for the conditions and replace, if necessary:

following

•

Corroded connectors and green, gray or white deposits on metal terminals.

•

Terminals incorrectly latched in connector body or pushed back relative to other terminals in same connector.

•

Make sure that each connector has its seals in place. During disassembly, a seal may pull off its connector and remain in mating socket of a sensor or actuator. A connector assembled without the correct seals can be contaminated with moisture and have corroded terminals, causing a poor electrical connection.

Sensors and Valves 1. Check all connector pins on sensors and valves. If bent or corroded, replace damaged component. 2. Remove scale or carbon build up. 3. Check for body cracks and leakage. 4. If orifices or valves are plugged, replace sensors or valves.

Engine Control Module (ECM) 1. Inspect rubber seal on harness connector and in ECM pin recesses. 2. Check for bent pins in ECM connections.


ENGINE ELECTRICAL

89

Installation Engine Control Module (ECM) and Support CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and free connectors or clips.

Figure 89 1. 2.

Figure 88 1. 2. 3. 4.

ECM support

ECM mounting bolts


4. Place ECM in position on support and install eight M6 x 30 bolts hand tight.

Cold Start Solenoid (CSS) ECM support Cold Start Relay (CSR) M8 x 40 bolt (3) with EDC bracket insulator (6)

1. Place ECM support in position on engine and install six EDC bracket insulators and three M8 x 40 bolts. Tighten bolts to special torque (page 106). 2. Install CSS on ECM support. See (Fuel Supply Solenoid Hose, page 111) in “COLD START ASSIST” section to install CSS. 3. Install CSR on ECM support. See (Relay Assembly, page 110) in “COLD START ASSIST” section to install CSR. Figure 90 1. 2.

ECM bolt tightening sequence


5. Tighten M6 x 30 bolts in sequence shown to special torque (page 106).


ENGINE ELECTRICAL

90 Engine Sensor (Wiring) Harness

1. Place sensor harness in position on engine using care to properly route it around and between components.

Figure 91 1. 2.

Sensor harness attachment points at left rear

M8 x 16 bolt (2) Tie strap (3)

3. 4.

M8 stud Harness clips

2. Install two M8 x 16 bolts to attach harness bracket to crankcase. Tighten bolts to special torque (page 106).

5.

21-way connector

5. Attach 21-way connector to harness bracket. 6. At left rear, connect harness connectors at CMP, CKP, ECT1 sensors and EGR valve.

3. Attach harness clip to M8 stud at coolant manifold. 4. Install three tie straps to secure sensor harness to harness support and coolant manifold.


ENGINE ELECTRICAL

Figure 92 1.

91

Sensor harness attachment points at left front (air intake throttle duct removed for clarity)

Tie strap (3)

2.

M6 x 16 bolt

7. Install M6 x 16 bolt to attach harness clip to coolant outlet manifold. Tighten bolt to standard torque (page 471).

3.

Other attachments

9. Install other attachments as necessary. 10. Connect harness connectors at EGRT, CACOT, IMP, RFP, FDP and EOL sensors.

8. Install three tie straps to secure sensor harness to back of air intake throttle duct and back and bottom of ECM support.


ENGINE ELECTRICAL

92

Figure 93 1.

Sensor harness attachment points at right front

Tie strap (4)

2.

M8 x 12 bolt

11. Install two M8 x 16 bolts to attach harness clip to EGR module cover. Tighten bolts to special torque (page 106). 12. Install M8 x 12 bolt to attach harness clip to EGR cooler low-temperature housing. Tighten bolt to standard torque (page 471).

3.

M8 x 16 bolt (2)

13. Install tie straps to secure sensor harness at ACV, EGR cooler, CCV and to air supply tube. 14. Connect harness connectors at IAT, MAF, TC2CIS, EOP, ACV, ECT2, CCOSS, CCV and EOT terminals.


ENGINE ELECTRICAL Engine Injector (Wiring) Harness

93

1. Check that 32.92 x 3.53 O-ring is in position on collar of harness mounting flange and in good condition. Replace as necessary. 2. Carefully route injector harness through valve cover base opening and along valve cover base to injectors.

Figure 94 Engine injector (wiring) harness O-ring location 1. 2. 3. 4.

Engine injector (wiring) harness Harness mounting flange 32.92 x 3.53 O-ring Harness flange collar


ENGINE ELECTRICAL

94

Figure 95 1.

Injector harness attachment points at cylinder head

Tie strap (7)

2.

Injector harness nut (12)

3. Install four M6 x 16 bolts to attach injector harness mounting flange to valve cover base. Tighten bolts to standard torque (page 471). 4. Install tie strap to secure injector at center of cylinder head.

3.

M6 x 16 bolt (4)

5. Install tie straps at six locations to secure injector harness to valve cover base. 6. Install 12 harness nuts to connect harness leads to injector terminals.


ENGINE ELECTRICAL

95

Wiring Harness ECM Connections

Figure 96 at ECM 1. 2.

Injector harness attachment points

Injector harness M6 x 30 bolt (2)

7. Install two M6 x 30 bolts to attach engine injector harness retainer clips to ECM. Tighten bolts to special torque (page 106).

Figure 97 1. 2. 3. 4. 5.

ECM harness connectors

ECM Engine injector harness connector (to ECM 16-pin E2 terminal) ECM 58-pin C2 chassis terminal ECM 58-pin C1 chassis terminal Engine sensor harness connector (to ECM 96-pin E1 terminal)

1. Check that ECM E1 and E2 terminal pins are straight and undamaged. 2. Align engine sensor harness connector with ECM E1 terminal and push connector straight in to engage pins. Push down on lock lever to draw in and secure connector.


ENGINE ELECTRICAL

96

1. Place TC2CIS sensor in position on air supply duct and install two M6 x 16 bolts. Tighten bolts to special torque (page 106). 2. Connect harness to TC2CIS terminal by pushing in on connector until a click is heard. 3. Push in yellow tab to lock connector.


Figure 98 1. 2.

Injector harness connector

Lock lever Connector clip

3. Align engine injector harness connector with ECM E2 terminal and push connector straight in to engage pins. Push down on lock lever to draw in and secure connector. Install connector clip. 4. Connect chassis harness connectors to ECM 58–pin C1 and C2 terminals. Lock connectors in place.


Figure 100 1. 2.

EGRT sensor

EGR module cover EGRT sensor

1. Install EGRT sensor in module cover. Tighten sensor to special torque (page 106). 2. Connect harness to EGRT sensor terminal by pushing in on connector until a click is heard. 3. Push in red tab to lock connector.

Figure 99 1. 2.

TC2CIS

M6 x 16 bolt (2) TC2CIS


ENGINE ELECTRICAL

97


Air Control Valve (ACV)

1. Install dual flap EGR valve. For EGR valve installation see (EGR Dual Flap Valve, page 261) in “EXHAUST GAS RECIRCULATION (EGR) SYSTEM” for procedure.

1. Install ACV. For air control valve installation see (Air Control Valve, page 143) in “EXHAUST BACK PRESSURE CONTROL” for procedure.


EGR valve harness connector

Harness connector EGR valve

2. Connect harness to EGR valve terminal by pushing in on connector until a click is heard.

1. 2.

ACV

Harness connector ACV assembly

2. Connect harness to ACV terminal by pushing in on connector until a click is heard.

3. Engage release tab.


ENGINE ELECTRICAL

98 Coolant Control Valve (CCV)

Engine Throttle Valve (ETV)

NOTE: The coolant mixer and coolant flow valves are not serviced separately. Both valves are an integral part of the CCV assembly which is available as a unit.

1. See (Air Intake Throttle Duct, page 277) in the “AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD” section for installation of air intake throttle duct and ETV as an assembly.

1. See Coolant Control Valve (CCV) in the “FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED COMPONENTS” section for installation.


CCV

1. 2.

ETV

ETV harness connector ETV

Coolant Mixer Valve (CMV) terminal Coolant Flow Valve (CFV) terminal

2. Connect harness to ETV terminal by pushing in on connector until a click is heard. 2. Connect harness CMV and CFV terminals by pushing in until a click is heard. 3. Engage release tab and secure CMV and CFV terminals to wiring harness.

3. Engage release tab. 4. See (Intake Manifold Pressure (IMP) Sensor, page 100) and (Charger Air Cooler Outlet Temperature (CACOT) Sensor, page 100) for installation of ETV-mounted sensors.


ENGINE ELECTRICAL Oxygen Sensor (O2S)


Figure 106 Figure 105 clarity) 1. 2. 3.

99

IMT sensor

O2S (valve actuator removed for

Exhaust back pressure valve housing O2S (with harness lead) Harness clip (2)

1. If removed, install new O2S. Tighten O2S to special torque (page 106). 2. Attach clips to secure harness lead to coolant tube and valve actuator bracket and at left rear of engine. 3. Connect harness to O2S terminal end by pushing in on connector until a click is heard.

1. Install new 16.7 x 24 seal ring and IMT sensor. Tighten sensor to special torque (page 106). NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly. 2. Connect harness connector to IMT sensor. 3. Turn IMT sensor harness connector locking ring 90° clockwise.

Rail Fuel Pressure (RFP) Sensor

4. Engage release lever. NOTE: Any time the O2S is replaced, an Oxygen Sensor Calibration Procedure must be done. See MaxxForce® 11 and 13 Engine Diagnostic Manual EGES-470 for details.

Figure 107

RFP sensor (typical)


ENGINE ELECTRICAL

100

1. Remove Disposable Air and Fuel Cap from fuel rail port and install RFP sensor.

Charger Air Cooler Outlet Temperature (CACOT) Sensor

2. Tighten sensor to special torque (page 106). 3. Connect harness to RFP sensor terminal by pushing in on connector until a click is heard. 4. Push in yellow tab to lock sensor connector.

Intake Manifold Pressure (IMP) Sensor

Figure 109 1. 2. 3.

Figure 108 1. 2. 3.

IMP sensor

IMP sensor Standoff tie strap Harness connector

1. Install new O-ring and install IMP sensor in ETV housing. Tighten sensor to special torque (page 106).

CACOT

CACOT sensor Harness connector Standoff tie strap

1. Install new 2.2 x 9.3 ID O-ring and CACOT sensor in throttle valve housing. Tighten sensor to special torque (page 106). 2. Connect harness to CACOT sensor terminal by pushing in on connector until a click is heard. 3. Engage release tab. 4. Attach tie strap to secure harness standoff bracket to CACOT sensor.

2. Connect harness to IMP sensor terminal by pushing in on connector until a click is heard. 3. Engage release tab. 4. Attach tie strap to secure harness standoff bracket to IMP sensor.


ENGINE ELECTRICAL

101

Humidity / Air Inlet Temperature (IAT) Sensor


Figure 110

Figure 111

1. 2. 3.

IAT

M6 x 16 bolt (2) Harness connector IAT

1. 2. 3.

MAF sensor

M4 x 0.7 cap screw (2) MAF sensor Harness connector

1. Insert new O-ring and place IAT in position on air inlet duct.

1. Install new 2.62 x 26.64 ID O-ring and place MAF sensor in position on air inlet duct.

2. Install two M6 x 16 bolts. Tighten bolts to special torque (page 106).

2. Install two M4 x 0.7 cap screws. Tighten cap screws to special torque (page 106).

3. Connect harness to IAT terminal by pushing in on connector until a click is heard.

3. Connect harness to MAF sensor terminal by pushing in on connector until a click is heard.

4. Push in yellow tab to lock sensor connector.

4. Push in yellow tab to lock sensor connector.


ENGINE ELECTRICAL

102 Fuel Pressure Control Valve (FPCV)

1. See (High-pressure Fuel Pump (HPFP) and Drive Housing, page 210) in the “FUEL SYSTEM” section for installation of high-pressure fuel pump.

1. Install FDP sensor and new 18.7 x 26 seal ring. Tighten sensor to special torque (page 106). NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly. 2. Connect harness to FDP sensor. 3. Turn sensor harness connector locking ring 90° clockwise.

Crankcase Oil Separator Speed (CCOSS) Sensor

Figure 112 1. 2.

FPCV (on high-pressure fuel pump)

FPCV Harness connector

2. Connect harness to FPCV terminal by pushing in on connector until a click is heard. 3. Push in yellow tab to lock sensor connector.

Fuel Delivery Pressure (FDP) Sensor

Figure 114 1. 2. 3.

CCOSS sensor

CCOSS sensor Oil centrifuge (part of oil module assembly) M6 x 14 bolt and nut

1. Place CCOSS sensor in position on bracket and install M6 x 14 bolt and nut. 2. Tighten bolt to special torque (page 106). 3. Connect harness to CCOSS sensor by pushing in on connector until a click is heard. 4. Push in yellow tab to lock connector in place.

Figure 113

FDP sensor EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

ENGINE ELECTRICAL

103

Engine Oil Pressure (EOP) Sensor


Figure 115

Figure 116

1. 2.

EOP sensor

Oil module assembly EOP sensor

1. 2.

EOT sensor

EOT sensor Oil module flange

1. Install EOP sensor and new 18.7 x 26 seal ring in oil module assembly. Tighten sensor to special torque (page 106).

1. Install EOT sensor and new 16.7 x 24 seal ring in oil module flange. Tighten sensor to special torque (page 106).

NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.


2. Connect harness to EOP sensor.

2. Connect harness to EOT sensor.

3. Turn sensor connector locking ring 90° clockwise.



ENGINE ELECTRICAL

104



Figure 117

Figure 118

ECT2 sensor

ECT1 sensor

1. Install ECT2 sensor and new 16.7 x 24 seal ring in EGR module low-temperature housing. Tighten sensor to special torque (page 106).

1. Install ECT1 sensor with new 16.7 x 24 seal ring in EGR coolant manifold at rear of engine. Tighten sensor to special torque (page 106).



2. Connect harness to ECT2 sensor.

2. Connect harness connector to ECT1 sensor.


3. Turn sensor harness connector locking ring 90° clockwise.


ENGINE ELECTRICAL

105

Camshaft Position (CMP) Sensor


Figure 119

Figure 120

CMP sensor (typical)

1. Lubricate new O-ring with oil-based grease and install on CMP sensor.

1. 2. 3. 4.

CKP sensor (typical)

Locking tab M6 x 16 bolt CKP sensor CKP harness connector

2. Insert CMP sensor in port at left rear of cylinder head. 3. Install M6 x 12 bolt to attach CMP sensor to head. Tighten bolt to special torque (page 106). 4. Connect harness to CMP sensor terminal by pushing in on connector until a click is heard. 5. Push in yellow tab to lock sensor connector in place.

1. Lubricate new O-ring with oil-based grease and install on CKP sensor. 2. Insert CKP sensor in port at top left of flywheel housing. 3. Install M6 x 16 bolt to CKP sensor. Tighten bolt to special torque (page 106). 4. Connect harness to CKP sensor terminal by pushing in on connector until a click is heard. 5. Push in yellow tab to lock connector in place.


ENGINE ELECTRICAL


Engine Electrical

Camshaft Position (CMP) sensor, M6 x 12 bolt

8 N·m (71 lbf·in)

Charger Air Cooler Outlet Temperature (CACOT) sensor

11 N·m (97 lbf·in)

Crankcase Oil Separator Speed (CCOSS) sensor, M6 x 14 bolt

10 N·m (89 lbf·in)

Crankshaft Position (CKP) sensor, M6 x 16 bolt Engine Control Module (ECM), M6 x 30 bolt

8 N·m (71 lbf·in) 10 N·m (89 lbf·in) See procedure for tightening sequence

Engine Control Module (ECM) support, M8 x 40 bolt

35 N·m (26 lbf·ft)

Engine Coolant Temperature 1 (ECT1) sensor

45 N·m (33 lbf·ft)


45 N·m (33 lbf·ft)

Engine injector harness retainer clip, M6 x 30 bolt

10 N·m (89 lbf·in)

Engine Oil Pressure (EOP) sensor

45 N·m (33 lbf·ft)

Engine Oil Temperature (EOT) sensor

45 N·m (33 lbf·ft)

Engine sensor harness bracket/clip, M8 x 16 bolt

35 N·m (26 lbf·ft)

Exhaust Gas Recirculation Temperature (EGRT) sensor

37 N·m (27 lbf·ft)

Fuel Delivery Pressure (FDP) sensor

45 N·m (33 lbf·ft)

Humidity / Air Inlet Temperature (AIT) sensor, M6 x 16 bolt Intake Manifold Temperature (IMT) sensor

9 N·m (80 lbf·in) 45 N·m (33 lbf·ft)

Intake Manifold Pressure (IMP) sensor

12 N·m (106 lbf·in)

Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw

0.36 N·m (3 lbf·in)

Oxygen Sensor (O2S) Rail Fuel Pressure (RFP) sensor Turbocharger 2 Compressor Inlet Sensor (TC2CIS), M6 x 16 bolt

50 N·m (37 lbf·ft) 140 N·m (103 lbf·ft) 9 N·m (80 lbf·in)


Engine Electrical

Description

Tool Number



ZTSE4891

COLD START ASSIST

107

Table of Contents

Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Glow Plug and Fuel Supply Cold Start Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Glow Plug and Fuel Supply Cold Start Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117


108

COLD START ASSIST


COLD START ASSIST

109

Exploded View

Figure 121 1. 2. 3. 4. 5.

Cold start assist components

Glow plug Fuel supply cold start hose Solenoid valve Washer (seal ring) (2) M8 x 1 banjo bolt

6. 7. 8. 9. 10.

M6 x 20 bolt (4) Relay assembly Banjo 8 bolt (M12 x 1.5) Seal 12.7 x 18 ring (2) Wiring DMR 11-13 x 6-6.5 clip

11. Fuel supply solenoid hose 12. Banjo 6 bolt (M10 x 1) 13. Seal 10.7 x 16 ring (2)


COLD START ASSIST

110

Removal

Relay Assembly 1. Disconnect wiring harness connector from relay assembly, if not already done.


WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. Figure 122 WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.

1. 2. 3.

Relay assembly

Engine Control Module (ECM) support bracket M6 x 20 bolt (2) Relay assembly

2. Remove two M6 x 20 bolts and remove relay assembly from ECM support bracket.


COLD START ASSIST

111

Glow Plug and Fuel Supply Cold Start Hose

Fuel Supply Solenoid Hose

Figure 123 hose

Figure 124 Fuel supply solenoid hose (at fuel filter housing)

1. 2. 3. 4. 5.

Glow plug and fuel supply cold start

Glow plug Fuel supply cold start hose Solenoid valve M8 x 1 banjo bolt Washer (seal ring) (2)

WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container designed for and clearly marked diesel fuel.

1. 2. 3. 4.

Fuel filter housing Seal 12.7 x 18 ring (2) Banjo 8 bolt (M12 x 1.5) Fuel supply solenoid hose

WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container designed for and clearly marked diesel fuel.

1. Place suitable container clearly marked DIESEL FUEL under fuel supply cold start hose.

1. Place suitable container clearly marked DIESEL FUEL under lower end of fuel supply solenoid hose.

2. Loosen hose fitting nut that attaches to glow plug fitting. Drain fuel into container.

2. Remove banjo 8 bolt (M12 x 1.5) from fuel filter housing and drain fuel into container.

3. Loosen and remove M8 x 1 banjo bolt securing fuel supply cold start hose to solenoid valve. Remove hose and discard two washers (seal rings).

3. Remove hose from filter housing and discard two seal 12.7 x 18 rings.


COLD START ASSIST

112

Figure 125 Fuel supply solenoid hose (at solenoid valve) 1. 2. 3. 4. 5.

Solenoid valve Seal 10.7 x 16 ring M6 x 20 bolt (2) Fuel supply solenoid hose (tube) Banjo 6 bolt (M10 x 1)

4. Remove banjo 6 bolt (M10 x 1) from solenoid valve. 5. Remove fuel supply solenoid hose from valve and discard two seal 10.7 x 16 rings.

Figure 126 1. 2. 3. 4.

Fuel supply solenoid hose clips

Clips on electrical harness (2) Clip on fuel filter bracket Fuel supply solenoid hose (tube) Clip on fuel HP pump drain hose

6. Remove fuel supply solenoid hose from four clips. 7. Remove two M6 x 20 bolts securing the solenoid valve to the ECM bracket. Remove valve.


COLD START ASSIST

113

Glow Plug

2. Loosen glow plug locking nut.

1. If not already done, disconnect the wiring harness lead from the glow plug.

3. Remove glow plug from air intake throttle duct by rotating counterclockwise.

Figure 127 1. 2. 3.

Glow plug

Glow plug Air intake throttle duct (horizontal shown) Glow plug locking nut


COLD START ASSIST

114

Installation

Fuel Supply Solenoid Hose

Glow Plug

Figure 128 1. 2. 3.

Glow plug

Glow plug Air intake throttle duct (horizontal shown) Glow plug locking nut

1. Install glow plug hand tight on air intake throttle duct. 2. Check that glow plug is properly oriented for connection of fuel supply hose and tighten glow plug locking nut to special torque (page 117).

Figure 129 Fuel supply solenoid hose (at solenoid valve) 1. 2. 3. 4. 5.

Solenoid valve Seal 10.7 x 16 ring (12) M6 x 20 bolt (2) Fuel supply solenoid hose (tube) Banjo 6 bolt (M10 x 1)

1. Install solenoid valve to ECM support bracket using two M6 x 20 bolts. Finger-tighten bolts. 2. Tighten M6 x 20 bolts to special torque (page 117). 3. Position fuel supply solenoid hose banjo fitting on solenoid valve port. Install two new seal 10.7 x 16 rings and banjo 6 bolt (M10 x 1) into solenoid valve.


COLD START ASSIST

115

5. Tighten banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts to special torque (page 117).

Figure 130 Fuel supply solenoid hose (at fuel filter housing) 1. 2. 3. 4.

Fuel filter housing Seal 12.7 x 18 ring (2) Banjo 8 bolt (M12 x 1.5) Fuel supply solenoid hose (tube)

4. Position fuel supply solenoid hose banjo fitting on port at bottom of fuel filter housing. Install two new seal 12.7 x 18 rings and banjo 8 bolt into fuel filter housing.

Figure 131 1. 2. 3. 4.

Fuel supply solenoid hose clips

Clips on electrical harness (2) Clip on fuel filter bracket Fuel supply solenoid hose Clip on fuel HP pump drain hose

6. Install fuel supply solenoid hose to four clips.


COLD START ASSIST

116

Glow Plug and Fuel Supply Cold Start Hose

Figure 132 hose 1. 2. 3. 4. 5.

Relay Assembly

Glow plug and fuel supply cold start

Glow plug Fuel supply cold start hose Solenoid valve M8 x 1 banjo bolt Washer (seal ring) (2)

Figure 133 1. 2. 3.

Relay assembly

ECM support M6 x 20 bolt (2) Relay assembly

1. Position fuel supply cold start hose onto solenoid valve port.

1. Position relay assembly on mounting pad at rear of ECM support.

2. Install two new washers (seal rings) and M8 x 1 banjo bolt. Tighten banjo bolt to special torque (page 117).

2. Install two M6 x 20 bolts. Tighten bolts to special torque (page 117).

3. Install fuel supply cold start hose onto glow plug fitting. Tighten fitting nut to special torque (page 117).

3. Refer to Engine Electrical (page 61) for wiring harness connection.

4. Refer to Engine Electrical section (page 61) for wiring harness connection.


COLD START ASSIST

117

Special Torque Table 5

Cold Start Assist

Banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts

15 N·m (11 lbf·ft)

Banjo M8 x 1 bolt

8 N·m (71 lbf·in)

Fuel supply cold start hose fitting nut

10 N·m (11 lbf·ft)

Glow plug locking nut

25 N·m (18 lbf·ft)

Relay assembly M6 x 20 bolts

10 N·m (89 lbf·in)

Solenoid valve M6 x 20 bolts

6 N·m (53 lbf·in)


118

COLD START ASSIST


AFTERTREATMENT SYSTEM

119

Table of Contents

Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Supply Fuel After Filter Hose and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Metering Unit Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 HCI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 HCI Coolant Return Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Hydrocarbon Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Hydrocarbon Injector Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Metering Unit Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Hydrocarbon Injector Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Hydrocarbon Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 HCI Coolant Return Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 HCI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 HCI Fuel Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136


120




121

Illustrations

Figure 134 1. 2. 3. 4.

Aftertreatment system components

Straight fitting HCI coolant supply tube assembly Tube M10 elbow fitting (coolant supply and return) (2) Hydrocarbon injector (HCI)

5. 6. 7. 8. 9. 10.

Tube clamp (2) Hose clamp (spring type) Pipe single cushioned clamp M8 x 16 bolt Hydrocarbon injector gasket M8 x 45 bolt (2)

11. 12. 13. 14.

HCI coolant return tube HCI fuel 2 tube assembly P 6 x 15 clamp M6 x 40 bolt



122

Figure 135 1. 2. 3. 4. 5. 6.

Aftertreatment system fuel supply

Metering unit valve assembly M8 x 35 bolt (3) Cushioned 1/4 inch diameter clamp M10 x 16 bolt P 6 x 15 clamp (2) M6 x 16 bolt (2)

7. 8. 9.

HCI fuel tube bracket assembly HCI fuel 2 tube assembly Fitting (quick-connect adapter) (contains port O-ring seal) 10. Fitting (straight union orifice) (contains port and fitting O-rings) 11. Clamp (to fuel drain tube)

12. 13. 14. 15.

Supply fuel after filter hose HCI fuel 1 tube assembly Metering unit bracket M8 x 16 bolt (4)



Removal

123

Supply Fuel After Filter Hose and Tubes


WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING: To prevent personal injury or death, remove ground cable from negative terminal of main battery before disconnecting or connecting electrical components. Always connect ground cable last.

Figure 136 Supply fuel after filter hose connection 1. 2. 3.

Fitting (quick-connect adapter) Metering unit valve assembly Supply fuel after filter hose

WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container designed for and clearly marked DIESEL FUEL. CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel compatible O-rings and O-ring seals. The specific Navistar P/N must be used for service. 1. Place suitable container clearly marked DIESEL FUEL under metering unit valve assembly.


124


Figure 138 Hydrocarbon injector (HCI) fuel 1 and 2 tube assemblies Figure 137 Fuel Line Disconnect Tool 11.8 mm on fuel supply hose 1. 2.

Fuel Line Disconnect Tool 11.8 mm Supply fuel after filter hose quick-connect fitting

2. Using Fuel Line Disconnect Tool 11.8 mm (page 136), disconnect supply fuel after filter hose from metering unit valve assembly.

1. 2. 3. 4. 5. 6. 7. 8.

HCI fuel 1 tube assembly nut Metering unit valve assembly P-clamp (2) HCI fuel 2 tube assembly fitting (brazed to tube) HCI fuel 1 tube assembly nut M6 x 16 bolt (2) M10 x 16 bolt Cushioned 1/4 inch diameter clamp

3. Loosen HCI fuel 1 tube assembly nut and disconnect tube from fitting assembly at metering unit valve assembly. 4. Remove M6 x 16 bolt, M10 x 16 bolt, P-clamp and cushioned 1/4 inch diameter clamp from HCI fuel 1 tube assembly.



Figure 139 1. 2. 3. 4.

125

HCI fuel 1 tube assembly connection

HCI fuel 1 tube assembly HCI fuel 2 tube assembly HCI fuel 1 tube assembly nut M6 x 16 bolt

5. Loosen HCI fuel 1 tube assembly nut and disconnect fuel tube from HCI fuel 2 tube assembly. 6. Remove M6 x 16 bolt, P-clamp and HCI fuel 1 tube assembly.

Figure 140 1. 2. 3. 4. 5. 6.

HCI fuel 2 tube assembly

6.6 x 15 x 23 spacer (2) M6 x 40 bolt (2) HCI fuel 2 tube assembly nut P 6 x 15 clamp (2) HCI fuel 2 tube assembly Hydrocarbon injector assembly

7. Loosen HCI fuel 2 tube assembly nut and disconnect tube from hydrocarbon injector assembly. 8. Remove two M6 x 40 bolts, two 6.6 x 15 x 23 spacers and remove HCI fuel 2 tube assembly.



126 Metering Unit Valve Assembly

Figure 142 Metering unit valve assembly (adapter/unions)

Figure 141 1. 2.

Metering unit valve assembly

Metering unit valve assembly M8 x 35 bolt (3)

CAUTION: To prevent component damage, keep metering unit valve assembly and related components clean and protected from damage until ready to install. Do not let dirt or other debris, lubricants or water get into fuel passages. Do not blow compressed air into fuel passages. If protection caps are used, they should be new, or ultrasonically cleaned before using. CAUTION: To prevent component damage, do not drop metering unit valve assembly onto a hard surface. If this happens, replace the valve. 1. Remove three M8 x 35 bolts and metering unit valve assembly. 2. If necessary, remove four M8 x 16 bolts and metering unit bracket. (Figure 135).

1. 2. 3. 4. 5. 6.

Fitting (quick-connect adapter) Metering unit valve assembly O-ring seal (orifice fitting) Fitting (straight union orifice) O-ring (# 011) O-ring seal (adapter)

NOTE: Do steps 3 and 4 only if metering unit valve assembly adapter or union fitting are leaking or if unit is being replaced. Use adapter and fitting on replacement unit. CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel compatible O-rings and O-ring seals. The specific Navistar P/N must be used for service. 3. Remove fitting (quick-connect adapter) from metering unit valve assembly. Remove and discard O-ring seal. 4. Remove fitting (straight union orifice) from metering unit. Remove and discard O-ring (# 011) and O-ring seal.



127

HCI Coolant Supply Tube Assembly

Figure 144 Figure 143 1. 2. 3. 4.

HCI coolant supply tube assembly

Straight fitting HCI coolant supply tube nut (at coolant manifold) HCI coolant supply tube assembly Tube M10 elbow fitting

1. Loosen the HCI coolant supply tube assembly nut and disconnect tube from tube M10 elbow fitting.

1. 2.

Hydrocarbon injector connection

Hydrocarbon injector Tube M10 elbow fitting

NOTE: Perform step 4 only if tube M10 elbow fitting is leaking or if hydrocarbon injector is being replaced. 4. Remove tube M10 elbow fitting from hydrocarbon injector.

2. Loosen coolant supply tube nut and disconnect tube from straight fitting at coolant manifold. Remove HCI coolant supply tube. 3. If necessary, remove straight fitting from coolant manifold.



128

HCI Coolant Return Tube Assembly

3. Release HCI coolant return tube from two tube clamps at open breather tube. 4. Loosen hose clamp (spring type). Separate HCI coolant return tube from open breather tube. Remove from engine.

Figure 145 1. 2. 3. 4. 5. 6. 7. 8.

HCI coolant return tube assembly

HCI coolant return tube nut Tube M10 elbow fitting Pipe single cushion clamp M8 x 16 bolt HCI coolant return tube assembly Tube clamp (2) Open breather tube Hose clamp (spring type)

Figure 146 Hydrocarbon injector tube M10 elbow fitting 1. 2.

Hydrocarbon injector Tube M10 elbow fitting

NOTE: Perform step 5 only if tube M10 elbow fitting is leaking or if hydrocarbon injector is being replaced. 1. Loosen HCI coolant return tube assembly nut and disconnect tube from tube M10 elbow fitting.

5. Remove tube M10 elbow fitting from hydrocarbon injector.

2. Remove M8 x 16 bolt from pipe single cushion clamp. Separate clamp from tube as necessary.


AFTERTREATMENT SYSTEM Hydrocarbon Injector

129

Cleaning and Inspection Hydrocarbon Injector Cleaning

Figure 147 1. 2. 3.

Hydrocarbon injector

M8 x 45 bolt (2) Hydrocarbon injector gasket Thermal management valve housing

CAUTION: To prevent component damage, keep hydrocarbon injector and related components clean and protected from damage until ready to install. Make sure to protect the injector nozzle tip as well as sealing and threaded surfaces. Do not let dirt or other debris, lubricants or water get into fuel or coolant passages. Do not blow compressed air into injector fuel passage. If protection caps are used, they should be new, or ultrasonically cleaned before using. CAUTION: To prevent component damage, do not drop hydrocarbon injector (especially nozzle tip) onto a hard surface. If this happens, replace the injector.

Figure 148 1. 2.


Hydrocarbon injector Injector nozzle tip

CAUTION: To prevent component damage, cleaning of the hydrocarbon injector using carb and choke cleaner, other solvents or using any brush is NOT recommended. It is not considered a regular maintenance procedure, nor is the injector considered a serviceable item. Do not blast the injector with compressed air. Do not pull or otherwise manipulate the injector nozzle tip. There is no acceptable cleaning method for the hydrocarbon injector. If in doubt, do not clean the injector, replace it.

1. Remove two M8 x 45 bolts and hydrocarbon injector from valve housing. Discard bolts. 2. Remove hydrocarbon injector gasket and save the used gasket for reuse during the hydrocarbon injector flow test.



130

Installation Metering Unit Valve Assembly

2. Lubricate a new O-ring (#011) with P-80® rubber lubricant or equivalent (page 136) and install into new fitting (straight union orifice). 3. Lubricate a new O-ring seal with P-80® rubber lubricant or equivalent (page 136) and install onto new fitting (straight union orifice) to metering unit valve assembly. Tighten to special torque (page 136). 4. If removed, position metering unit bracket and install four M8 x 16 bolts. Tighten bolts to standard torque (page 471)

Figure 149 Metering unit valve assembly (adapter/unions) 1. 2. 3. 4. 5. 6.

Fitting (quick-connect adapter) Metering unit valve assembly O-ring seal Fitting (straight union orifice) O-ring (# 011) O-ring seal

NOTE: Do steps 1 and 2 only if fitting (quick-connect adapter) or fitting (straight union orifice) are removed or metering unit valve assembly is replaced. CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel compatible O-rings and O-rings seals. The specific Navistar P/N must be used for service. 1. Lubricate a new O-ring seal with P-80® rubber lubricant or equivalent (page 136) and install onto fitting (quick-connect adapter). Install fitting to metering unit valve assembly. Tighten to special torque (page 136).

Figure 150 1. 2.

Metering unit valve assembly

Metering unit valve assembly M8 x 35 bolt (3)

5. Install metering unit valve assembly and three M8 x 35 bolts. Tighten bolts to standard torque (page 471).



131

Hydrocarbon Injector

Figure 151 Metering unit valve assembly connections 1. 2. 3.

Supply fuel after filter hose quick-connect fitting Electrical connections (4) Metering unit valve assembly

6. Position supply fuel after filter hose onto fitting (quick-connect adapter) and push on until click is heard or felt. 7. Reconnect wiring harness to four electrical connections.

Hydrocarbon Injector Flow Test Before installing hydrocarbon injector onto engine, perform a flow test using Hydrocarbon Injector Flow Test Kit ZTSE6069. See EGES-470 MaxxForce® 11 and 13 Engine Diagnostic Manual for Hydrocarbon Flow Test setup and procedure.

Figure 152 1. 2. 3.


M8 x 45 bolt (2) Hydrocarbon injector gasket Thermal management valve housing

1. Position hydrocarbon injector and gasket onto the thermal management valve housing. Install two new M8 x 45 bolts and tighten as follows. a. Pre-tighten bolts to 11 N·m (97 lbf·in). b. Final-tighten bolts to 25 N·m (18 lbf·ft). Do not over tighten. NOTE: Do steps 2 and 3 only if fittings were removed or if hydrocarbon injector was replaced.


132

AFTERTREATMENT SYSTEM HCI Coolant Return Tube Assembly

Figure 153 Hydrocarbon injector tube M10 elbow fittings 1. 2. 3.

Hydrocarbon injector Tube M10 elbow fitting (coolant out) Tube M10 elbow fitting (coolant in)

2. Install tube M10 elbow fitting (coolant in) into hydrocarbon injector and finger-tighten. 3. Install tube M10 elbow fitting (coolant out) into hydrocarbon injector and finger-tighten.

Figure 154 1. 2. 3. 4. 5. 6. 7. 8.

HCI coolant return tube assembly

HCI coolant return tube nut Tube M10 elbow fitting Pipe single cushion clamp M8 x 16 bolt HCI coolant return tube assembly Tube clamp (2) Open breather tube Hose clamp (spring type)

NOTE: Do steps 1 and 2 if tube M10 elbow fitting was removed or if hydrocarbon injector was replaced. Otherwise, skip to step 3. 1. Install tube M10 elbow fitting onto hydrocarbon injector and tighten fitting to maintain orientation and clearance for HCI coolant return tube assembly. 2. Tighten tube M10 elbow fitting to special torque (page 136). 3. Position HCI coolant return tube assembly onto open breather tube nipple, two tube clamps on open breather tube and pipe single cushion clamp. 4. Install M8 x 16 bolt through pipe single cushion clamp and tighten to standard torque (page 471). EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved


133

5. Snap HCI coolant return tube into two tube clamps and install hose clamp (spring type) to secure tube to open breather tube.

1. If previously removed, install straight fitting into coolant manifold and tighten to special torque (page 136).

6. Tighten HCI coolant return tube assembly nut onto tube M10 elbow fitting (orient fitting as needed to reduce tube stress and to not contact other components) and tighten tube nut and elbow fitting each to special torque (page 136).

2. Loosely install HCI coolant supply tube nut onto straight fitting at coolant manifold.

HCI Coolant Supply Tube Assembly

NOTE: Do steps 3 and 4 if tube M10 elbow fitting was removed or if hydrocarbon injector was replaced. Otherwise, skip to step 5. 3. Install tube M10 elbow fitting onto hydrocarbon injector and tighten fitting to maintain orientation and clearance for HCI coolant supply tube assembly. Tighten tube M10 elbow fitting to special torque (page 136). 4. Loosely install HCI coolant supply tube nut onto tube M10 elbow fitting (orient fitting as needed) on hydrocarbon injector. 5. Tighten two HCI coolant supply tube nuts to special torque (page 136).

Figure 155 1. 2. 3. 4.

HCI coolant supply tube assembly

Straight fitting HCI coolant supply tube nut (at coolant manifold) HCI coolant supply tube assembly Tube M10 elbow fitting



134 HCI Fuel Tube Assembly

Figure 157

Figure 156 1. 2. 3. 4. 5.

1. 2. 3. 4. 5. 6. 7.

HCI fuel 2 tube assembly

6.6 x 15 x 23 spacer (2) M6 x 40 bolt (2) HCI fuel 2 tube assembly nut P 6 x 15 clamp (2) HCI fuel 2 tube assembly

1. Position HCI fuel 2 tube assembly onto engine. 2. Connect HCI fuel 2 hydrocarbon injector.

tube

assembly

onto

3. Install two M6 x 40 bolts, 2 clamps and two 6.6 x 15 x 23 spacers. Tighten bolts to standard torque (page 471).

HCI fuel 1 and 2 tube assemblies

HCI fuel 1 tube assembly nut (2) Metering unit valve assembly P 6 x 15 clamp (2) HCI fuel 2 tube assembly fitting (brazed to tube) M6 x 16 bolt (2) M10 x 16 bolt Cushioned 1/4 inch diameter clamp

5. Position HCI fuel 1 tube assembly to engine. Loosely connect fuel 1 tube with fuel 2 tube and metering unit valve assembly. 6. Install two M6 x 16 bolts, one M10 x 16 bolt, two P 6 x 15 clamps and cushioned 1/4 inch diameter clamp. Tighten bolts to standard torque (page 471) .

4. Using a wrench, hold the hydrocarbon injector hex to keep it from rotating. Tighten HCI fuel 2 tube nut to special torque (page 136), while holding the injector body hex.



135

7. Tighten HCI fuel 1 tube assembly nut at HCI fuel 2 tube nut (brazed) to special torque (page 136). 8. Tighten HCI fuel 1 tube assembly nut at metering unit valve assembly to special torque (page 136). 9. Connect clamp from fuel drain tube to HCI fuel 1 tube assembly.

Figure 158 1. 2. 3. 4.

Fuel supply assembly connection

HCI fuel 1 tube assembly HCI fuel 2 tube assembly HCI fuel 1 tube assembly nut M6 x 16 bolt




Aftertreatment System

Coolant supply (straight) fitting at coolant manifold

35 N·m (26 lbf·ft)

Fitting (quick-connect adapter) at metering unit valve assembly

35 N·m (26 lbf·ft)

Fitting (straight union orifice) at metering unit valve assembly

35 N·m (26 lbf·ft)

HCI coolant supply and return tube nut at tube M10 elbow fittings

15 N·m (11 lbf·ft)

HCI coolant supply tube nut at coolant manifold

25 N·m (18 lbf·ft)

HCI fuel 1 tube assembly nut at HCI fuel 2 tube fitting (brazed)

25 N·m (18 lbf·ft)

HCI fuel 1 tube assembly nut at metering unit valve assembly

25 N·m (18 lbf·ft)

HCI fuel 2 tube assembly nut at hydrocarbon injector

18 N·m (13 lbf·ft)

Hydrocarbon injector M8 x 45 bolt Hydrocarbon injector body to assembly (if accidentally loosened during fuel tube nut service) Tube M10 elbow fittings at hydrocarbon injector

See tightening steps in procedure. 20 N·m (15 lbf·ft) 17.5 N·m (13 lbf·ft)



Description

Tool Number

Fuel Line Disconnect Tool 11.8 mm

ZTSE4773

Hydrocarbon Injector Flow Test Kit

ZTSE6069

P-80® rubber lubricant or equivalent

Obtain locally


EXHAUST BACK PRESSURE CONTROL

137

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Air Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes. . . . . .141 Exhaust Back Pressure Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Exhaust Back Pressure Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Air Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes. . . . . .143 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146


138




139

Exploded Views

Figure 159 1. 2. 3. 4. 5.

Exhaust back pressure control system

Air control valve M8 x 85 bolt (2) M6 x 40 bolt (2) Exhaust back pressure valve tube bracket (2) Spacer (2)

6. 7. 8. 9.

Exhaust back pressure valve tube assembly Tube bracket TC1 turbine outlet pressure (TC1TOP) sensor tube assembly Flare M10 x 1.5 (37 degree) fitting

10. Exhaust back pressure valve assembly 11. M8 x 45 bolt (7) 12. Spacer (7) 13. Flare M10 x M12 (24 degree) fitting



140

Removal

Air Control Valve


WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 160 1. 2. 3. 4. 5. 6. 7. 8.

Air control valve tubes and hoses

M8 x 85 bolts (2) Air control valve Low-pressure wastegate actuator hose High-pressure wastegate actuator hose Air supply tube connection Exhaust back pressure valve tube TC1 turbine outlet pressure (TC1TOP) sensor tube Crimp clamp (2)

1. Cut two crimp clamps securing high-pressure and low-pressure wastegate actuator hoses. Discard two crimp clamps and separate hoses from air control valve.

NOTE: Refer to the following service sections for information on removal of components prior to this section:

2. Loosen TC1TOP sensor tube nut and exhaust back pressure tube nut. Disconnect tubes from control valve.

•

Engine Electrical

CAUTION: Relieve system pressure before loosening air supply tube valve.

•


3. Loosen air supply tube nut from air control valve. Disconnect air supply tube from control valve. 4. Disconnect air supply tube nut from bulkhead fitting. Cut any tie straps and remove tube if necessary. 5. Remove two M8 x 85 bolts and control valve.


EXHAUST BACK PRESSURE CONTROL Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes

141

2. Loosen TC1TOP sensor tube nut from low-pressure turbocharger housing flare M10 x M12 (24 degree) fitting and disconnect tube. 3. If necessary, remove flare M10 x M12 (24 degree) fitting.

Figure 161 Exhaust back pressure valve actuator and TC1 turbine outlet pressure (TC1TOP) sensor tubes 1. 2. 3. 4.

Exhaust back pressure valve tube nut Exhaust back pressure valve actuator TC1TOP sensor tube nut Flare M10 x M12 (24 degree) fitting

1. Loosen exhaust back pressure valve tube nut from exhaust back pressure valve actuator and disconnect tube.

Figure 162 TC1TOP sensor and exhaust back pressure valve tubes 1. 2. 3. 4. 5.

TC1TOP sensor tube bracket M6 x 40 bolt (2) Exhaust back pressure valve tube bracket (2) Exhaust back pressure valve tube TC1TOP sensor tube

4. Remove two M6 x 40 bolts, exhaust back pressure valve tube and TC1TOP sensor tube.



142

Exhaust Back Pressure Valve Assembly

Installation Exhaust Back Pressure Valve Assembly

Figure 163 assembly 1. 2. 3.

Exhaust back pressure valve

M8 x 45 bolt (7) Spacer (7) Exhaust back pressure valve assembly

1. Remove seven M8 x 45 bolts, seven spacers and exhaust back pressure valve assembly.


Exhaust back pressure valve

M8 x 45 bolt (7) Spacer (7) Exhaust back pressure valve assembly

1. Install exhaust back pressure valve assembly, using seven M8 x 45 bolts and seven spacers. Tighten bolts to special torque (page 146).



143

Install air control valve and two M8 x 85 bolts. Tighten bolts to standard torque (page 471).

Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes

Figure 165 Exhaust back pressure valve actuator lubrication points

2. Apply Superlub™ synthetic high heat lubricant (page 146) or equivalent to areas indicated.

Air Control Valve

Figure 167 Exhaust back pressure valve actuator and TC1 turbine outlet pressure (TC1TOP) sensor tubes 1. 2. 3. 4.

Exhaust back pressure valve tube nut Exhaust back pressure valve actuator TC1TOP sensor tube nut Flare M10 x M12 24 degree fitting

1. Install exhaust back pressure valve tube nut onto exhaust back pressure valve actuator. Leave loose at this time.

Figure 166 1. 2.

Air control valve

Air control valve M8 x 85 bolt (2)


144


2. If removed, install and tighten flare M10 x M12 (24 degree) fitting to special torque (page 146). 3. Position TC1TOP sensor tube nut to low-pressure turbocharger housing flare M10 x M12 (24 degree) fitting. Leave loose at this time.

Figure 169

Figure 168 TC1TOP sensor and exhaust back pressure valve actuator tubes 1. 2. 3. 4. 5.

TC1TOP sensor tube bracket M6 x 40 bolt (2) Exhaust back pressure valve tube bracket (2) Exhaust back pressure valve tube TC1TOP sensor tube

4. Position exhaust back pressure valve tube and TC1TOP sensor tube against EGR cooler. Using two M6 x 40 bolts and two spacers, secure tubes to EGR cooler. Tighten bolts to standard torque (page 471).

1. 2. 3. 4. 5. 6. 7. 8.

Air control valve tubes and hoses

M8 x 85 bolts (2) Air control valve Low-pressure wastegate actuator hose High-pressure wastegate actuator hose Air supply tube connection Exhaust back pressure valve tube TC1 turbine outlet pressure (TC1TOP) sensor tube Crimp clamp (2)

5. Position TC1TOP sensor and exhaust back pressure valve tubes. Install tube nuts and tighten to special torque (page 146). 6. Tighten exhaust back pressure valve tube nut at valve actuator and TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting to special torque (page 146).



7. Install air supply tube nut to air control valve and tighten tube nut to special torque (page 146). 8. If removed, position air supply tube to engine. Install tube nut to bulkhead fitting and tighten to special torque (page 146). Install tie straps to brackets as necessary.

145

9. Install crimp clamps on turbocharger high- and low-pressure actuator hoses. Position actuator hoses to air control valve ports. Using crimping pliers, tighten the clamps.




Exhaust Back Pressure Control

Air supply tube (at bulkhead fitting)

17.5 N·m (13 lbf·ft)

Air supply tube nut (at air control valve)

12 N·m (106 lbf·in)

Exhaust back pressure valve assembly mounting bolts, M8 x 45 Exhaust back pressure valve tube nut (at actuator)

25 N·m (18 lbf·ft)

Exhaust back pressure valve tube nut (at air control valve) Flare M10 x M12 (24 degree) fitting

15 N·m (11 lbf·ft)

15 N·m (11 lbf·ft)

17.5 N·m (13 lbf·ft)

TC1TOP sensor tube nut (at air control valve)

15 N·m (11 lbf·ft)

TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting

15 N·m (11 lbf·ft)



Description

Tool Number

Crimping pliers

Obtain locally

Superlub™ synthetic high heat lubricant

Obtain locally


TURBOCHARGERS

147

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 High-pressure (HP) and Low-pressure (LP) Wastegate Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 Low-pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156 Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 High-pressure (HP) Compressor Out Duct and Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 High-pressure Turbocharger Air Supply Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 Turbocharger Oil Return and Oil Supply Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 Turbocharger Heat Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 Turbocharger Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 Turbocharger Wastegate Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 Turbocharger Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 Turbochargers and Related Parts Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 Turbocharger Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 Low-pressure Charge Air Cooler (LPCAC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167 Turbocharger Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167 Turbocharger Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 Turbocharger Wastegate Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 Turbocharger Heat Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170 Turbocharger Oil Return and Oil Supply Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171 High-pressure Turbocharger Air Supply Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 High-pressure (HP) Compressor Out Duct and Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 Low-pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 High-pressure (HP) and Low-pressure (LP) Wastegate Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179


148

TURBOCHARGERS


TURBOCHARGERS

149

Exploded Views

Figure 170 1. 2. 3. 4. 5. 6. 7.

Turbochargers and charge air cooler assembly

Rear exhaust manifold Wastegate high-pressure actuator High-pressure turbocharger assembly Air inlet duct M8 x 16 bolt Cab heater return tube assembly Air supply high-pressure turbocharger duct

8. 9. 10. 11.

O-ring M6 x 20 bolt M10 x 20 x 35 stud bolt High-pressure compressor out duct 12. Inlet (and outlet) high-pressure compressor seal 13. M10 x 40 bolt 14. Low-pressure charge air cooler

15. Low-pressure turbocharger assembly 16. Turbocharger oil supply tube assembly 17. Wastegate low-pressure actuator


TURBOCHARGERS

150

Figure 171 1. 2. 3. 4. 5. 6. 7.

Coolant tube, coolant hoses and low-pressure charge air cooler (LPCAC)

LPCAC air inlet Intake O-ring (low-pressure turbocharger to LPCAC) Low-pressure charge air cooler Coolant return hose (CAC to coolant return duct) M24 x 1.5 threaded fitting (2) Coolant return duct (integral with air supply duct) 3/4 inch constant torque hose clamp (7)

8. 9. 10. 11. 12. 13. 14.

Coolant return hose (at EGR cooler) Coolant tube (EGR cooler to LPCAC) Tube support Air supply high-pressure turbocharger duct M10 x 200 bolt (2) M8 x 20 bolt Coolant return hose (to water distribution housing)

15. Hose clamp (1 inch worm gear) 16. 72.2 x 60 (DMR) tube seal (extension tube) 17. LPCAC air outlet (to air supply high-pressure turbocharger duct) 18. Coolant hose (coolant tube to CAC water inlet) 19. M10 x 100 bolt 20. Ground stud bolt (2) 21. EGR cooler assembly


TURBOCHARGERS

Figure 172 1. 2. 3. 4.

151

Turbocharger oil supply tube and support bracket

High-pressure turbocharger assembly M6 x 16 bolt (2) Turbocharger supply seal (2) Turbocharger oil supply tube assembly

5. 6. 7. 8.

Male stud connector (on crankcase) Low-pressure turbocharger assembly M8 x 40 bolt M8 x 16 bolt

9. M8 x 40 x 15 stud bolt 10. 19 x 20 spacer (2) 11. Turbocharger support bracket


TURBOCHARGERS

152

Figure 173 1. 2. 3.

Turbocharger oil return tubes

High-pressure turbocharger assembly Turbocharger oil drain gasket (2) M8 x 20 bolt (4)

4. 5. 6.

Oil return high-pressure turbocharger tube Metric bonded seal washer 24.7 x 32 seal ring

7. 8.

Oil return low-pressure turbocharger tube Low-pressure turbocharger assembly


TURBOCHARGERS

Figure 174 1. 2. 3. 4. 5. 6.

153

Air inlets, actuators and air control valve

High-pressure wastegate hose Cable lock strap (3) Air control valve assembly 12.3 x 7 crimp clamp (4) Inlet high-pressure compressor seal Air inlet duct

7.

Air supply high-pressure turbocharger duct 8. Low-pressure wastegate hose 9. Inlet low-pressure compressor seal 10. Wastegate high-pressure actuator

11. Cable lock strap (6) 12. Wrap insulator 13. Wastegate low-pressure actuator 14. M8 x 14 bolt (6) 15. Seal ring (2) 16. M24 threaded fitting (2)


TURBOCHARGERS

154

Figure 175 1. 2. 3. 4. 5.

Turbochargers

M8 x 16 bolt (3) High-pressure turbocharger heat shield 10.5 x 20 x 15 sleeve (2) High-pressure turbocharger assembly Dowel pin (2)

6. 7. 8. 9.

M10 x 45 stud M10 nut (3) M8 x 14 bolt (6) Wastegate high-pressure actuator 10. Turbocharger heat shield 11. M8 x 16 bolt (2)

12. Wastegate low-pressure actuator 13. M10 x 55 bolt (5) 14. Low-pressure turbocharger assembly


TURBOCHARGERS


155

NOTE: Refer to the following service sections for information on removal of components prior to this section. •

Engine Electrical

•


•


•

Oil Cooler, Ventilation

Filter Housing and Crankcase

High-pressure (HP) and Low-pressure (LP) Wastegate Hoses

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, remove ground cable from negative terminal of main battery before disconnecting or connecting electrical components. Always connect ground cable last. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

Figure 176 1. 2. 3. 4.

HP and LP wastegate hoses

Cable lock strap (9) 12.3 x 7 crimp clamp (2) HP wastegate hose LP wastegate hose

1. Cut and remove crimp clamps and disconnect HP and LP wastegate hoses from wastegate actuators. 2. Cut and discard nine cable lock straps. 3. Note routing of wastegate hoses for later reassembly. Remove HP and LP wastegate hoses. 4. Inspect hoses (and wrap insulator) for damage or deformation and replace if necessary.


TURBOCHARGERS

156

Low-pressure Charge Air Cooler (LPCAC)

Figure 178 Figure 177 LPCAC and coolant hose connections 1. 2. 3. 4. 5. 6.

Coolant hose (supply) M10 x 100 bolt Low-pressure charge air cooler Ground stud bolt (2) 3/4 inch constant torque hose clamp (2) Coolant return hose

1. 2. 3. 4. 5. 6. 7.

LPCAC

O-ring seal LPCAC air inlet 72.2 x 60 (DMR) tube seal (extension tube) LPCAC air outlet Low-pressure charge air cooler Coolant return Coolant supply

6. Remove LPCAC from engine. NOTE: Refer to "OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION" for removal of the open breather tube assembly and related components. 1. Loosen 3/4 inch hose clamp and disconnect coolant hose (supply) from LPCAC. 2. Loosen 3/4 inch hose clamp and disconnect coolant return hose from LPCAC.

CAUTION: To prevent engine damage, do not remove extension tube by grabbing sealing surface. 7. Remove 72.2 x 60 (DMR) tube seal (extension tube) from LPCAC. Do so by inserting pry bar handle (or wooden dowel) into tube seal and carefully prying side-to-side to lift tube from LPCAC. Inspect sealing surfaces of tube seal (extension tube) and LPCAC. Discard if damaged. 8. Remove O-ring seal from LPCAC and discard.

3. Remove M10 x 100 bolt from LPCAC. 4. Remove two M10 stud bolts from LPCAC. 5. Pull down to separate LPCAC from LP turbocharger and air supply HP turbocharger duct.


TURBOCHARGERS

157

Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses

Figure 180 Figure 179 1. 2. 3. 4.

1. 2. 3. 4. 5. 6. 7.

Coolant return hose

3/4 inch constant torque hose clamp (2) Low temperature housing (EGR cooler) Coolant return hose Coolant tube

1. Loosen two 3/4 inch hose clamps. 2. Disconnect coolant return hose from temperature housing and coolant tube.

Coolant and cab heater tubes

Cable lock strap (2) Coolant tube Tube support M8 x 20 bolt Cab heater return tube assembly M6 x 20 bolt 3/4 inch constant torque hose clamp

3. Cut two cable lock straps from coolant tube. low

4. Remove M8 x 20 bolt to release coolant tube support and cab heater return tube assembly retainer. 5. Remove M8 x 16 bolt and tube support behind air inlet duct. Remove M6 x 20 bolt to release cab heater return tube assembly and remove tube. Remove and discard O-ring. 6. Loosen 3/4 inch hose clamp and disconnect coolant tube from coolant hose. Remove coolant tube.


158

TURBOCHARGERS

Figure 181 Coolant return hose (at air supply high-pressure turbocharger duct) 1. 2. 3.

3/4 inch constant torque hose clamp Coolant return hose Air supply high-pressure turbocharger duct (coolant return integral with duct)

7. Loosen 3/4 inch hose clamp and disconnect coolant hose from air supply high-pressure turbocharger duct.

Figure 182 Coolant return hose (air supply duct to water distribution housing) 1. 2. 3. 4. 5.

Air supply high-pressure turbocharger duct (coolant return integral with duct) 3/4 inch constant torque hose clamp Water distribution housing 1 inch worm gear hose clamp Coolant return hose

8. Loosen 3/4 inch hose clamp, 1 inch hose clamp and disconnect coolant return hose from air supply duct and water distribution housing.


TURBOCHARGERS High-pressure (HP) Compressor Out Duct and Air Inlet Duct

159

4. Remove M8 x 45 bolt and M10 x 140 bolt. Remove air inlet duct from low-pressure turbocharger. 5. Remove LP compressor inlet seal from LP turbocharger compressor inlet and discard. High-pressure Turbocharger Air Supply Duct

Figure 183 duct 1. 2. 3. 4. 5. 6.

HP compressor out duct and air inlet

Air inlet duct M8 x 45 bolt M10 x 20 x 35 stud bolt M10 x 140 bolt HP compressor out (outlet) duct M10 x 40 bolt

1. Remove M10 x 40 bolt and M10 x 20 x 35 stud bolt. 2. Disconnect HP compressor out duct from HP turbocharger compressor outlet. Remove from engine. NOTE: The high-pressure compressor inlet seal is used in two places on the high-pressure compressor including both compressor inlet and outlet. 3. Remove high-pressure compressor inlet seal from compressor out duct and discard.

Figure 184 High-pressure (HP) turbocharger air supply duct 1. 2. 3. 4.

HP turbocharger air supply duct M10 x 200 bolt (2) High-pressure compressor inlet seal M24 threaded fitting

1. Remove two M10 x 200 bolts and turbocharger air supply duct from turbocharger.

HP HP

2. Remove HP compressor inlet seal and discard. 3. Only if required, remove M24 threaded fitting and discard seal ring.


TURBOCHARGERS

160

Turbocharger Oil Return and Oil Supply Tubes

Figure 185 1. 2. 3. 4. 5. 6.


High-pressure (HP) turbocharger oil return tube M8 x 20 bolt (4) Oil return tube fittings (2) Low-pressure (LP) turbocharger oil return tube 24.7 x 32 seal ring Turbocharger oil drain gasket (2)

Figure 186 1. 2. 3.

Turbocharger oil supply tube fitting

Turbocharger oil supply tube assembly Oil supply tube fitting Male stud connector

6. Loosen turbocharger oil supply tube fitting at male stud connector on crankcase. Disconnect tube fitting from crankcase connector.

1. Loosen LP turbocharger oil return tube fitting nut from HP turbocharger oil return tube. 2. Remove four M8 x 20 bolts and disconnect HP oil return tube from HP and LP turbocharger and LP oil return tube. 3. Remove and discard two turbocharger oil drain gaskets. 4. Remove and discard bonded seal washer between HP and LP turbocharger oil return tubes. 5. Remove LP turbocharger oil return tube from crankcase and discard 24.7 x 32 seal ring.

Figure 187 1. 2.

Turbocharger oil supply tube

Turbocharger oil supply tube assembly M6 x 16 bolt (2)


TURBOCHARGERS

161

7. Remove two M6 x 16 bolts from turbocharger oil supply tube at LP and HP turbochargers. Disconnect oil supply tube.

2. Remove two M8 x 16 bolts and turbocharger heat shield.

8. Remove and discard turbocharger supply seals from LP and HP turbocharger oil supply tube ends. Clean and inspect sealing surfaces.

Turbocharger Support Bracket

Turbocharger Heat Shields

Figure 189

Figure 188 1. 2. 3.

Turbocharger heat shields

M8 x 16 bolt (5) HP turbocharger heat shield Turbocharger heat shield

1. Remove three M8 x 16 bolts and HP turbocharger heat shield.

1. 2. 3. 4. 5.

Turbocharger support bracket

Turbocharger support bracket M8 x 16 bolt M8 x 40 bolt M8 x 40 x 15 stud bolt 19 x 20 spacer (2)

1. Remove M8 x 16 bolt at bottom of LP turbocharger. 2. Remove M8 x 40 bolt, M8 x 40 x 15 stud bolt, two spacers and support bracket.


TURBOCHARGERS

162 Turbocharger Wastegate Actuators

2. Remove three M8 x 14 bolts. 3. Remove HP wastegate actuator.

Figure 190 actuator 1. 2. 3.

High-pressure (HP) wastegate

M8 x 14 bolt (3) HP wastegate actuator C-clip

NOTE: It is not necessary to remove the wastegate actuator to remove the turbocharger. The turbocharger and wastegate actuator can be removed as an assembly. If the wastegate actuator is being replaced, proceed with the following steps. 1. Remove C-clip from HP actuator wastegate linkage.

Figure 191 actuator 1. 2. 3. 4.

Low-pressure (LP) wastegate

LP turbocharger assembly LP wastegate actuator linkage C-clip LP wastegate actuator M8 x 14 bolt (3)

4. Remove C-clip from LP wastegate actuator linkage. 5. Remove three M8 x 14 bolts. 6. Remove LP wastegate actuator.


TURBOCHARGERS

163

Turbocharger Mounting

Figure 193 High-pressure (HP) turbocharger mounting (upper nuts and sleeves) Figure 192 nut) 1. 2. 3.

HP turbocharger mounting (lower

HP turbocharger assembly M10 nut M10 x 45 stud

1. 2. 3.

M10 nut (2) 10.5 x 20 x 15 sleeve (2) HP turbocharger mounting flange

2. Remove two M10 nuts and two 10.5 x 20 x 15 sleeves. WARNING: To prevent personal injury or death, use suitable lifting equipment and get help to remove or install the turbochargers. 1. Get help from an turbochargers during M10 nut.

assistant removal.

to

3. Remove turbochargers from middle exhaust manifold.

support Remove


TURBOCHARGERS

164

Disassembly Turbochargers

1. Remove five M10 x 55 bolts and separate HP turbocharger from LP turbocharger. 2. Inspect mating flanges and two dowel pins for damage. Replace if necessary.

Figure 194 High-pressure (HP) and low-pressure (LP) turbocharger connection 1. 2. 3.

M10 x 55 bolt (5) HP turbocharger assembly LP turbocharger assembly


TURBOCHARGERS

Cleaning and Inspection Turbochargers and Related Parts Cleaning WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

165

NOTE: Replace turbochargers if blades are bent. Do not attempt to straighten bent impeller or turbine wheel blades. 3. Place turbochargers on a bench with the shafts in a horizontal position.

NOTE: Do not use a caustic solution on turbochargers and related components. 1. Clean ducting between air inlet duct and air cleaner assembly with soap and then, steam clean. Dry all ducting with filtered compressed air. 2. Clean Low-Pressure Charge Air Cooler (LPCAC), air inlet duct and air supply high-pressure turbocharger duct with filtered compressed air. 3. Clean turbocharger oil supply tube assembly and oil return turbocharger tubes with suitable solvent and a nylon brush. Dry tubes with filtered compressed air. Replace any damaged tubes. 4. Clean all gasket and O-ring sealing surfaces.

Turbocharger Inspection CAUTION: To prevent engine damage, do not damage compressor impeller or turbine wheel. If either is damaged, a new turbocharger must be installed.

Figure 195 Free rotation of turbocharger assembly shaft (typical)

4. Turn shafts by hand and check for impeller and wheel rub in the housings. The shaft, impeller and turbine must rotate freely. If there is any rubbing or interference, replace turbocharger.

1. Inspect turbochargers for cracks and leaks. Replace if necessary. 2. Inspect compressor impellers and turbine wheels for blade erosion, bends, breakage or deposits. Replace turbochargers if damaged.


166

TURBOCHARGERS

Low-pressure Charge Air Cooler (LPCAC) Pressure Test

Figure 196

LPCAC pressure test (typical)

1. Attach Charge Air Cooler Test Kit (page 179) to LPCAC using instructions supplied with tool and three inch couplers and clamps (obtain locally). WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

3. Spray a soapy water solution on LPCAC. Look for leaks from hose connections, LPCAC or test components. 4. If a leak is detected on LPCAC or test gauge pressure drops, replace LPCAC. 5. Remove Charge Air Cooler Test kit from LPCAC.

2. Pressurize LPCAC to 30 psi (207 kPa).


TURBOCHARGERS

167

Installation Turbocharger Mounting WARNING: To prevent personal injury or death, use suitable lifting equipment and get help to remove or install the turbochargers. WARNING: To prevent personal injury or death, do not allow the turbochargers to hang by the lower stud and nut alone. Support the assembly until the upper sleeves and nuts are installed.

Figure 198 1. 2. 3. 4. 5.

HP turbocharger alignment check

Crankcase-to-cylinder head deck Middle exhaust manifold Turbo Alignment Bracket (ZTSE6041) HP turbocharger Hand screw

2. With help of an assistant, align three studs and position HP turbocharger to middle exhaust manifold. Check that turbine exhaust outlet flange is aligned square with Turbo Alignment Bracket.

Figure 197 Turbocharger alignment tool installation 1. 2. 3. 4.

Crankcase-to-cylinder head deck Tab Turbo Alignment Bracket (ZTSE6041) Hand screw

1. Install Turbo Alignment Bracket ZTSE6041 on engine with tabs seated on crankcase-to-cylinder head deck. Thread tool hand screw into crankcase boss and tighten to secure bracket in place.

Figure 199 HP turbocharger mounting (upper nuts and sleeves) 1. 2. 3.

HP turbocharger mounting flange M10 nut (2) 10.5 x 20 x 15 sleeve (2)


TURBOCHARGERS

168

3. With turbocharger supported in place, install two 10.5 x 20 x 15 sleeves and two new M10 nuts on upper mounting studs. Finger-tighten nuts.

6. Remove Turbo Alignment Bracket (ZTSE6041) from engine.

Figure 201 Figure 200 nut) 1. 2.

HP turbocharger mounting (lower

M10 x 45 stud M10 nut

4. Install new M10 nut on lower mounting stud, finger tight. 5. With turbine exhaust outlet flange aligned square with Turbo Alignment Bracket, tighten three M10 nuts to standard torque (page 471).

1. 2. 3.

LP turbocharger installation

LP turbocharger assembly M10 x 55 bolt (5) HP turbocharger assembly

7. Align two dowel pins and support LP turbocharger in position on HP turbocharger turbine outlet flange. 8. Install five new M10 x 55 bolts and tighten to special torque (page 179).


TURBOCHARGERS

169

Turbocharger Support Bracket

Figure 203 actuator Figure 202 1. 2. 3. 4. 5.

Turbocharger support bracket

Turbocharger support bracket M8 x 16 bolt M8 x 40 bolt M8 x 40 x 15 stud bolt 19 x 20 spacer (2)

1. 2. 3. 4.

Low-pressure (LP) wastegate

LP turbocharger assembly LP wastegate actuator linkage C-clip LP wastegate actuator M8 x 14 bolt (3)

1. Position LP wastegate actuator with hose port facing down and install three M8 x 14 bolts. 1. Position turbocharger support bracket and install two 19 x 20 spacers, M8 x 40 x 15 stud bolt and M8 x 40 bolt. 2. Install M8 x 16 bolt into bottom of turbocharger. Tighten three bolts to standard torque (page 471).

Turbocharger Wastegate Actuators NOTE: If wastegate actuators have been removed from turbochargers, proceed with the following steps.

2. Tighten three bolts to special torque (page 179). 3. Position LP wastegate actuator linkage on wastegate lever pin. Install actuator linkage C-clip on wastegate lever pin. WARNING: To prevent personal injury or death, wear safety glasses with side shields. NOTE: Check wastegate actuator linkage movement using a hand pump or shop air regulated to no more than 345 kPa (50 psi). 4. Attach air source to LP wastegate actuator and operate actuator through full range and check for free movement. There should be smooth operation without binding. If operation is not smooth, loosen pushrod jam nut and retighten. Recheck movement.


TURBOCHARGERS

170

9. Attach air source to HP wastegate actuator and operate actuator through full range and check for free movement. There should be smooth operation without binding. If operation is not smooth, loosen pushrod jam nut and retighten. Recheck movement. Turbocharger Heat Shields

Figure 204 actuator 1. 2. 3.

High-pressure (HP) wastegate

M8 x 14 HP bolt (3) HP wastegate actuator C-clip

5. Position HP wastegate actuator with hose port facing up and install three M8 x 14 bolts. 6. Tighten three bolts to special torque (page 179). 7. Position wastegate HP actuator linkage on wastegate lever pin. 8. Install actuator linkage C-clip on wastegate lever pin.

Figure 205 1. 2. 3.

Turbocharger heat shields

M8 x 16 bolt (5) HP turbocharger heat shield Turbocharger heat shield

WARNING: To prevent personal injury or death, wear safety glasses with side shields.

1. Position turbocharger heat shield and install two M8 x 16 bolts. Tighten bolts to standard torque (page 471).

NOTE: Check wastegate actuator linkage movement using a hand pump or shop air regulated to no more than 345 kPa (50 psi).

2. Install HP turbocharger heat shield and three M8 x 16 bolts. Tighten bolts to standard torque (page 471).


TURBOCHARGERS

171

Turbocharger Oil Return and Oil Supply Tubes

Figure 206 1. 2.

Turbocharger oil supply tube

Turbocharger oil supply tube assembly M6 x 16 bolt (2)

Figure 207 1. 2. 3.

Turbocharger oil supply tube fitting

Turbocharger oil supply tube assembly Oil supply tube fitting Male stud connector

1. Lubricate two turbocharger supply seals (Figure 3, item 3) with P-80® rubber lubricant or equivalent (page 179).

4. If removed, install male stud connector and tighten to special torque (page 179).

2. Install new turbocharger supply seals on ends of the oil supply tube.

5. Position turbocharger oil supply tube fitting nut onto male stud connector on crankcase. Tighten fitting nut to special torque (page 179).

3. Position turbocharger oil supply tube onto turbochargers and install two M6 x 16 bolts. Tighten bolts to standard torque (page 471).


TURBOCHARGERS

172

a. Tighten fitting nut to 10 N·m (89 lbf·in). b. Turn fitting nut an additional 90°.

High-pressure Turbocharger Air Supply Duct

Figure 208 1. 2. 3. 4. 5. 6.


High-pressure (HP) turbocharger oil return tube M8 x 20 bolt (4) Oil return tube fittings (2) Low-pressure (LP) turbocharger oil return tube 24.7 x 32 seal ring Turbocharger oil drain gasket (2)

6. Install LP turbocharger oil return tube with new 24.7 x 32 seal ring into crankcase. Snug fitting only until final tightening. 7. Connect HP turbocharger oil return tube to LP turbocharger oil return tube with new bonded seal washer. Snug fitting only until final tightening. 8. Position HP turbocharger oil return tube with new oil drain gaskets to oil return outlet flanges of LP turbocharger and HP turbocharger. 9. Install four M8 x 20 bolts and tighten bolts to standard torque (page 471). 10. Final tighten LP turbocharger oil return tube fitting nut at crankcase fitting as follows: a. Tighten fitting nut to 10 N·m (89 lbf·in).

Figure 209 High-pressure (HP) turbocharger air supply duct 1. 2. 3. 4.

HP turbocharger air supply duct M10 x 200 bolt (2) High-pressure compressor inlet seal M24 threaded fitting

1. Lubricate new high-pressure compressor inlet seal with P-80® rubber lubricant or equivalent (page 179) and install over HP turbocharger compressor inlet groove. 2. Install HP turbocharger air supply duct along with two M10 x 200 bolts. Tighten bolts to standard torque (page 471). 3. If previously removed, install new seal ring and M24 threaded fitting and tighten to special torque (page 179).

b. Turn fitting nut an additional 90°. 11. Final tighten HP turbocharger oil return tube fitting nut at LP turbocharger oil return tube as follows:


TURBOCHARGERS High-pressure (HP) Compressor Out Duct and Air Inlet Duct

173

4. Install HP compressor out duct into HP turbocharger air outlet, install M10 x 40 bolt and M10 x 20 x 35 stud bolt and tighten to standard torque (page 471).

Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses

Figure 210 duct 1. 2. 3. 4. 5. 6.

HP compressor out duct and air inlet

Air inlet duct M8 x 45 bolt M10 x 20 x 35 stud bolt M10 x 140 bolt HP compressor out duct M10 x 40 bolt

Figure 211 Coolant return hose (air supply duct to water distribution housing) 1.

1. Lubricate a new LP compressor inlet seal with P-80® rubber lubricant or equivalent (page 179) and install seal over LP turbocharger compressor inlet. 2. Install air inlet duct to LP turbocharger. Install M8 x 45 bolt and M10 x 140 bolt. Tighten bolts to standard torque (page 471). NOTE: The high-pressure compressor inlet seal is used in two places on the high-pressure turbocharger compressor including both compressor inlet and outlet.

2. 3. 4. 5.

Air supply high-pressure (HP) turbocharger duct (coolant return integral with duct) 3/4 inch worm gear hose clamp Water distribution housing 1 inch worm gear hose clamp Coolant return hose

1. Install coolant return hose to water distribution housing and air supply duct. Install 3/4 inch hose clamp and 1 inch hose clamp. Tighten 3/4 inch and 1 inch hose clamps to special torque (page 179).

3. Lubricate new HP compressor inlet seal with P-80® rubber lubricant or equivalent (page 179) and install into groove in compressor out duct.


174

TURBOCHARGERS

Figure 212 Coolant return hose (air supply high-pressure turbocharger duct) 1. 2. 3.

3/4 inch worm gear hose clamp Coolant return hose Air supply HP turbocharger duct (coolant return integral with duct)

2. Install coolant return hose to air supply HP turbocharger duct. Install 3/4 inch hose clamp and loosely tighten at this time.

Figure 213 1. 2. 3. 4. 5. 6. 7.

Coolant and cab heater tubes

Cable lock strap (2) Coolant tube Tube support M8 x 20 bolt Cab heater return tube assembly M6 x 20 bolt 3/4 inch constant torque hose clamp

3. Lubricate new cab heater return tube O-ring with P-80® rubber lubricant or equivalent (page 179). 4. Install a new O-ring onto cab heater return tube assembly. 5. Position cab heater return tube assembly and install M6 x 20 bolt and M8 x 20 bolt through tube support behind air inlet duct. Tighten bolts to standard torque (page 471). 6. Install coolant hose onto lower end of coolant supply tube. Install 3/4 inch hose clamp onto hose and loosely tighten at this time. 7. Position coolant tube support and cab heater return tube assembly retainer and install M8 x 20 bolt. Tighten bolt to standard torque (page 471). NOTE: Two cable lock straps are installed later after LP wastegate hose is installed to secure hose to coolant tube.


TURBOCHARGERS

175

Low-pressure Charge Air Cooler (LPCAC)

Figure 214 1. 2. 3. 4.

Coolant return hose

3/4 inch worm gear hose clamp (2) Low-temperature housing (EGR cooler) Coolant return hose Coolant tube

8. Install coolant hose and two 3/4 inch hose clamps between coolant tube and low-temperature housing (EGR cooler).

Figure 215 1. 2. 3. 4. 5. 6. 7.

LPCAC

O-ring seal LPCAC air inlet 72.2 x 60 (DMR) tube seal (extension tube) LPCAC air outlet Low-pressure charge air cooler Coolant return Coolant supply

9. Tighten clamps to special torque (page 179). 1. Lubricate 72.2 x 60 (DMR) tube seal (extension tube) with P-80® rubber lubricant or equivalent (page 179) and install into LPCAC using Extension Tube Installer (page 179). 2. Lubricate new O-ring seal with P-80® rubber lubricant or equivalent (page 179) and install O-ring at LPCAC air inlet.


TURBOCHARGERS

176

3. Install LPCAC to engine until tube seal (extension tube) and O-ring are fully engaged with air duct and LP turbocharger. 4. Install two M10 stud bolts and M10 x 100 bolt. Tighten bolts to standard torque(page 471). 5. Connect coolant return hose to LPCAC and install 3/4 inch hose clamp. 6. Tighten two coolant return hose clamps to special torque (page 179). 7. Connect coolant (supply) hose to LPCAC and install 3/4 inch hose clamp. 8. Tighten two coolant (supply) hose clamps to special torque (page 179).

Figure 216 LPCAC and coolant hose connections 1. 2. 3. 4. 5. 6.

Coolant hose (supply) M10 x 100 bolt Low-pressure charge air cooler Ground stud bolt (2) 3/4 inch worm gear hose clamp (2) Coolant return hose


TURBOCHARGERS

177

High-pressure (HP) and Low-pressure (LP) Wastegate Hoses

Figure 217 1. 2. 3. 4.

HP and LP wastegate hoses

12.3 x 7 crimp clamp (2) Cable lock strap (11) EGRV coolant supply tube Air control valve assembly

5. 6. 7.

Coolant tube (EGR cooler to LPCAC) LP wastegate hose HP wastegate hose

8. 9.

Turbocharger oil supply tube HCI coolant return tube


178

TURBOCHARGERS

NOTE: Replace HP or LP wastegate hoses (or insulator wrap) if damaged or deformed. 1. Route HP and LP wastegate hoses onto engine as noted during removal. 2. Connect HP wastegate hose to HP wastegate actuator fitting. 3. Connect LP wastegate hose to LP wastegate actuator fitting.

5. Install five cable lock straps to secure HP wastegate hose to turbocharger oil supply tube and EGRV coolant supply tube. 6. Install six cable lock straps to secure LP wastegate hose to HCI coolant return tube and EGR cooler to LPCAC coolant tube. 7. Connect LP and HP wastegate hoses to air control valve. Refer to "EXHAUST BACK PRESSURE CONTROL" for procedure.

4. Install two new crimp clamps to secure hoses. Using crimping pliers (page 179), tighten the clamps.


TURBOCHARGERS

179


Turbochargers

3/4 inch and 1 inch worm gear hose clamps

3.5 N·m (31 lbf·in)

High-pressure-to-low-pressure turbine bolts, M10 x 55

47 N·m (35 lbf·ft)

Low-pressure and high-pressure wastegate actuator bolts, M8 x 14

16 N·m (12 lbf·ft)

Male stud connector

70 N·m (52 lbf·ft)

M24 threaded fitting

60 N·m (44 lbf·ft)

Oil return low-pressure turbocharger tube (at crankcase)

See tightening steps in procedure.

Oil return low-pressure turbocharger tube fitting nut


Turbocharger oil supply tube assembly fitting nut to male stud connector

27 N·m (20 lbf·ft)


Turbochargers

Description

Tool Number

3-inch couplers and clamps

Obtain locally

Charge Air Cooler Test Kit Crimping pliers

ZTSE6042 Obtain locally

Extension Tube Installer P-80® rubber lubricant or equivalent


Turbo Alignment Bracket


ZTSE6041

180

TURBOCHARGERS


AIR COMPRESSOR AND POWER STEERING

181

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 Power Steering and One-Cylinder Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 Power Steering and Two-Cylinder Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 All components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189 Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189 Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189 Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193


182




183

Exploded Views Power Steering and One-Cylinder Air Compressor

Figure 218 1. 2. 3. 4. 5. 6.

One-cylinder air compressor and power steering system (typical)

Extension clip M6 x 25 bolt Power steering (low-pressure) tube assembly M6 x 1.0 nut (2) Power steering pump M10 x 40 bolt (2)

7. 8. 9. 10. 11. 12. 13.

Lock washer (10 mm) (2) Return coolant tube assembly Return coolant hose assembly Air compressor M8 x 110 bolt (4) M8 x 40 bolt (2) Power steering pump adapter

Optional two-cylinder compressors are available. Although compressor housings are longer, compressor and power steering line connections to

14. 15. 16. 17.

O-ring seal 1/2” 90 degree tube elbow 1-1/16” 90 degree elbow Power steering (high-pressure) tube assembly 18. Support bracket 19. M16 straight union (2)

crankcase and chassis are similar to one-cylinder compressors.



184

Power Steering and Two-Cylinder Air Compressor

Figure 219 1. 2. 3. 4. 5. 6. 7. 8.

Optional two-cylinder air compressor and power steering system (typical)

Extension clip M6 x 25 bolt Power steering (low-pressure) tube assembly M6 x 1.0 nut (2) Power steering pump M10 x 40 bolt (2) Lock washer (10 mm) (2) Air compressor

9. O-ring seal (3) 10. M16 straight fitting (3) 11. 21 mm constant-tension clamp (4) 12. Coolant return hose 13. M16 45 degree fitting 14. Coolant supply hose 15. M8 x 40 bolt (2) 16. M8 x 110 bolt (4)

17. 18. 19. 20. 21. 22.

M10 x 110 bolt Power steering pump adapter O-ring seal 1/2” tube 90 degree elbow 1-1/16”-12ST 90 degree elbow Power steering (high-pressure) tube assembly 23. Support bracket



Removal

185

Power Steering Pressure Tubes


WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.

Figure 220 tubes 1. 2. 3. 4. 5.

Power steering pump and Pressure

Power steering pump High-pressure tube fitting nut 1/2” 90 degree tube elbow 1-1/6” 90 degree tube elbow Low-pressure tube fitting nut

1. Place a drain pan under the power steering pump to catch any fluid. 2. Loosen high-pressure tube fitting nut and disconnect tube from 1/2” 90 degree tube elbow. 3. Loosen low-pressure tube fitting nut and disconnect tube from 1-1/16” 90 degree elbow.



186

8. If equipped, remove front support brackets and rubber isolator from the high-pressure and low-pressure tubes.

Power Steering Elbows NOTE: This procedure should be completed only if replacing power steering pump, or if one or both of the elbows are leaking.

Figure 221 1. 2. 3. 4. 5. 6.

Pressure tubes support bracket

Power steering (low-pressure) tube assembly Extension clip M6 nut M6 x 20 stud Rear support bracket Power steering (high-pressure) tube assembly

Figure 222 elbows 4. Remove rear support bracket M6 nut from extension clip stud at the oil pan. 5. If equipped, remove front support bracket M6 nut from support bracket. 6. Remove high-pressure and low-pressure tubes as an assembly. NOTE: If replacing high-pressure and low-pressure tubes, do steps 7 and 8. 7. Remove the rear support brackets and rubber isolator from the high-pressure and low-pressure tubes.

1. 2. 3.

Power steering pump and 90 degree

Power steering pump 1/2” 90 degree tube elbow 1-1/16” 90 degree elbow

1. Loosen the lock nut and rotate the 1/2” 90 degree tube elbow counterclockwise to remove from power steering pump. 2. Loosen the lock nut and rotate the 1-1/16” 90 degree elbow counterclockwise to remove from power steering pump.


AIR COMPRESSOR AND POWER STEERING Power Steering Pump

Air Compressor Coolant Hoses

Figure 223

Figure 225

1. 2. 3.

Power steering pump

Power steering pump Air compressor M10 x 40 bolt and lock washer (2)

1. 2. 3.

1. Remove two M10 x 40 bolts, lock washers and power steering pump. 2. Check pump collar O-ring for damage and replace as necessary.

Figure 224 1. 2.

Power steering pump adapter

Power steering pump adapter Air compressor

3. Remove power steering pump adapter from air compressor bore.

187

Air compressor coolant hoses

Coolant return hose Coolant return tube (one cylinder air compressor) or Coolant supply hose (two cylinder air compressor) Air compressor

1. Place suitable container under air compressor to collect any residual coolant.

Figure 226 removal 1. 2.

Air compressor coolant hose

Coolant Line Release Tool Coolant hose

2. Insert Coolant Line Release Tool (page 193) into retaining clips of air compressor coolant hose and remove from crankcase.



188

3. Using Coolant Line Release Tool (page 193), release and remove air compressor coolant tube from air compressor. 4. Recycle or dispose of any coolant according to applicable regulations.

Air Compressor

WARNING: To prevent personal injury or death, get assistance to remove and install the air compressor and power steering pump assembly. NOTE: For two-cylinder air compressor only, an additional M10 x 110 bolt is located in the air compressor mounting hole next to the power steering pump. 1. For one-cylinder air compressor, remove two M8 x 40 bolts and four M8 x 110 bolts. 2. For two-cylinder air compressor, remove two M8 x 40 bolts, four M8 x 110 bolts and M10 x 110 bolt. 3. Remove air compressor from alignment dowels.

Cleaning All components 1. Cover coolant, fluid and air openings to ensure dirt does not enter air compressor and power steering pump.

Figure 227 1. 2.

Air compressor (typical)

2. Clean foreign material from sealing surfaces of air compressor. Use a scraper to clean sealing material from the sealing surfaces. 3. Use only hot water to clean all hoses and tubes.

M8 x 40 bolt (2) M8 x 110 bolt (4)



Installation

189

Air Compressor Coolant Hoses

Air Compressor

Figure 229 1. 2.

Figure 228 1. 2.

Air compressor (typical)

3.

Air compressor coolant hoses

Coolant return hose Coolant return tube (one-cylinder air compressor) or Coolant supply hose (two-cylinder air compressor) Air compressor

M8 x 40 bolt (2) M8 x 110 bolt (4)

1. Depending on compressor model, straight and 45° coolant fittings are used. If loosened, tighten fittings as follows: WARNING: To prevent personal injury or death, get assistance to remove and install the air compressor and power steering pump assembly. CAUTION: To prevent engine damage, install component within 5 minutes of sealant application to inhibit the formation of a skin and ensure a leak-proof joint. NOTE: For two-cylinder air compressor only, an additional M10 x 110 bolt is located in the mounting hole next to the power steering pump.

One-cylinder compressors •

Tighten M16 straight fittings (at crankcase or air compressor) to special torque (page 193).

•

If equipped, tighten M16 45° fitting (at crankcase) to special torque (page 193).

•

If equipped, tighten M18 straight fittings (at air compressor) to special torque (page 193).

Two-cylinder compressors

1. Apply Loctite® 5900 sealant or Wacker® A-442 RTV (page 193) to crankcase and air compressor mating surface.

•

Tighten M16 straight fittings (at crankcase or air compressor) to special torque (page 193).

•

2. For one-cylinder air compressor, position air compressor and install two M8 x 40 bolts and four M8 x 110 bolts. Tighten bolts to special torque (page 193).

If equipped, tighten M16 45° fitting (at crankcase or air compressor) to special torque (page 193).

2. Check air compressor coolant supply and return hose O-rings before installation. Replace O-rings as needed.

3. For two-cylinder air compressor, position air compressor and install two M8 x 40 bolts, four M8 x 110 bolts and M10 x 110 bolt. Tighten bolts to special torque (page 193).

3. Place coolant supply hose in position between crankcase and air compressor coolant fittings.



190

4. Press down on quick-connect fittings until a click is heard to install hose. Lightly pull on hose to make sure it is locked. 5. Repeat steps 3 and 4 to install air compressor coolant return hose.

Power Steering Pump

Figure 231 1. 2. 3.

Power steering pump (typical)

Power steering pump Air compressor M10 x 40 bolt (2)

2. If pump collar O-ring was removed or damaged, install a new O-ring. Lubricate the new O-ring with P80® rubber lubricant (page 193) or equivalent. Figure 230 1. 2.

Power steering pump adapter

Power steering pump adapter Air compressor

3. Install power steering pump and two M10 x 40 bolts. Tighten bolts to special torque (page 193).

Power Steering Elbows 1. Install power steering pump adapter to air compressor bore.

Figure 232 1. 2. 3.

Power steering elbows

Power steering pump 1/2” 90 degree tube elbow 1-1/16” 90 degree elbow


AIR COMPRESSOR AND POWER STEERING NOTE: This procedure should be completed only if replacing power steering pump, or if one or both of the elbows were removed. 1. Check seals on elbow for damage. Replace as necessary. 2. Install 1/2” 90 degree tube elbow to power steering pump. Lock nuts should not be tightened until power steering lines are installed for proper orientation.

191

Power Steering Pressure Tubes NOTE: If high-pressure and low-pressure tubes were replaced, do steps 1 and 2. 1. If equipped and removed, install front support brackets and rubber isolator onto the high- and low-pressure tubes. 2. If removed, install rear support brackets and rubber isolator onto the high- and low-pressure tubes.

3. Install 1-1/16” 90 degree elbow to power steering pump. Lock nuts should not be tightened until power steering lines are installed for proper orientation.



192

Figure 234 Figure 233 1. 2. 3. 4. 5. 6.

Pressure tubes support bracket

High- and low-pressure tube assembly Extension clip M6 x 1.0 nut M6 x 20 bolt Rear support bracket Power steering (high-pressure) tube assembly

3. Position high-pressure and low-pressure tube as an assembly. Install M6 x 1.0 nut onto extension clip stud to secure rear support bracket at the oil pan. Tighten nut to standard torque (page 471). 4. If equipped, install front support bracket to extension clip stud on front engine support and secure with M6 x 1.0 flange nut. Tighten nut to standard torque (page 471).

1. 2. 3. 4. 5.

Pressure tubes

Power steering pump High-pressure tube 1/2” 90 degree tube elbow 1-1/16” 90 degree elbow Low-pressure tube

NOTE: Do the following steps if fittings were removed or if power steering pump was replaced. 5. Loosely install the high-pressure tube fitting nut to the elbow. Using an appropriate size wrench to hold the elbow, tighten 1/2" 90 degree tube elbow lock nut to special torque (page 193). 6. Loosely install the low-pressure tube fitting nut to the elbow. Using an appropriate size wrench to hold the elbow, tighten 1-1/16" 90 degree elbow lock nut to special torque (page 193). 7. Tighten the high-pressure and low-pressure tube fitting nuts to special torque (page 193).



193


Air Compressor and Power Steering/Fuel Pump

1-1/16" 90 degree elbow lock nut

55 N·m (40 lbf·ft)

1/2" 90 degree tube elbow lock nut

45 N·m (33 lbf·ft)

Air compressor M8 x 40, M8 x 110 bolt (one cylinder)

35 N·m (26 lbf·ft)

Air compressor M8 x 40, M8 x 110 bolt (two cylinder)

31 N·m (23 lbf·ft)

(Two cylinder) Air compressor M10 x 110 bolt

67 N·m (49 lbf·ft)

High-pressure tube fitting nut

62 N·m (45 lbf·ft)

M16 straight fitting

35 N·m (26 lbf·ft)

M16 45° fitting

17.5 N·m (13 lbf·ft)


37.5 N·m (28 lbf·ft)

Low-pressure tube fitting nut

164 N·m (120 lbf·ft)

Power steering pump M10 x 40 bolt

67 N·m (49 lbf·ft)


Air Compressor

Description

Tool Number

Coolant Line Release Tool

ZTSE4778

Loctite® 5900 sealant or Wacker® A-442 RTV

Obtain locally

P80® rubber lubricant or equivalent

Obtain locally


194



FUEL SYSTEM

195

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 Fuel Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 Fuel Filter Stand Pipe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 High-pressure Pump (Drive Belt) Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209 High-pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . .210 High-pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 Low-pressure and High-pressure Fuel System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 Fuel Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216 High-pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 High-Pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . .223 High-Pressure Pump (Drive Belt) Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 Fuel Primer Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 Fuel Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228 Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 Filter and Fuel Strainer Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234


196

FUEL SYSTEM


FUEL SYSTEM

197

Exploded Views

Figure 235 1. 2. 3. 4. 5. 6. 7. 8.

High-pressure fuel lines

Thrust washer (6) Injector hold-down clamp (6) Rounded washer (6) M8 x 50 bolt (6) Injector (6) 3 x 20.9 ID O-ring (6) Combustion washer (6) Pressure limiting valve (fuel rail)

9. 10. 11. 12. 13.

Fuel to rail supply clamp assembly (2) High-pressure pump to rail tube assembly 2 High-pressure pump to rail tube assembly 1 M8 x 40 bolt (3) Fuel rail

14. Rail fuel pressure sensor 15. High-pressure rail to injector tube assembly (6) 16. High-pressure connector retaining nut (6) 17. 13.5 x 3 O-ring (6) 18. High-pressure connector body (6)


FUEL SYSTEM

198

Figure 236 1. 2. 3.

Fuel supply and drain (return) lines

After-filter fuel supply hose (assembly) Pre-pump fuel supply hose assembly Pre-filter fuel supply hose (assembly)

4. 5. 6. 7.

Fuel drain (return) hose assembly Fuel filter bracket assembly with brace M14 banjo bolt (3) Seal ring, 14.7 x 22 (6)

8. 9. 10. 11. 12.

Fuel drain (return) tube assembly Closed (P) clamp and 8 x 16 bolt Wiring clip 8 x 13 single retainer C-clip


FUEL SYSTEM

Figure 237 1. 2. 3. 4. 5. 6. 7. 8.

199

Fuel filter housing assembly

Priming cup cap Priming element Priming pump M8 x 25 bolt (2) M8 x 30 bolt (4) 9 ID x 18 OD x 10.5 spacer (3) Fuel filter bracket assembly with brace 9 ID x 17 OD x 6.5 spacer

9. 10. 11. 12. 13. 14. 15. 16. 17.

Fuel filter cap Fuel filter cap O-ring Fuel filter element Fuel filter housing assembly Threaded union (3) Seal ring, 14.7 x 22 (12) M14 x 1.5 hex socket plug Fuel filter drain plug M8 x 45 bolts (3)

18. Fuel Delivery Pressure (FDP) sensor 19. Fuel supply adapter 20. Banjo fitting 21. Check valve (quick connect) 22. Dust cap 23. Fuel filter stand pipe


FUEL SYSTEM

200

Figure 238 1. 2. 3. 4.

High-pressure fuel pump and drive housing

M24 jam nut Washer, 25 x 44 x 4 High-pressure (fuel) pump gear High-pressure (fuel) pump drive housing 5. M12 x 90 bolt 6. 100 x 3.349 O-ring 7. High-pressure fuel pump 8. Seal ring, 16.7 x 24 (4) 9. Quick-connect M16 x 1.5 connector (4) 10. M14 x 30 bolt (2)

11. High-pressure (fuel) pump support 12. M12 x 30 bolt (2) 13. M10 x 40 bolt (4) 14. M12 x 130 bolt (2) 15. M12 x 40 bolt 16. Drive belt shaft 17. 30.2 x 3 O-ring 18. Sleeve 19. High-pressure pump (drive belt) pulley housing 20. M10 x 40 bolt (4)

21. 55 x 70 x 8 radial shaft seal 22. High-pressure pump (drive belt) pulley 23. M16 x 40 LH bolt (left-hand thread)


FUEL SYSTEM


WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components.

201

WARNING: To prevent personal injury or death, remove ground cable from the negative terminal of main battery before disconnecting or connecting electrical components. Always connect ground cable last. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING: To prevent personal injury or death, do not turn ignition key to ON if fuel system parts are removed or disconnected. Activation of the fuel pump could spill fuel and create a fire. NOTE: Refer to the following service sections for information on removal of components prior to this section. •

Engine Electrical

•

Cold Start Assist

•


•

Turbochargers


FUEL SYSTEM

202 High-pressure Fuel Lines

WARNING: To prevent personal injury or death, engine must be stationary for at least 5 minutes before doing any work on high-pressure fuel system to allow for system depressurization. WARNING: To prevent personal injury or death, whenever any fuel line (tubing) in the high-pressure fuel system is removed, it must be replaced with new. CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed. 1. If not already done, disconnect air supply line from harness 21-way connector bracket.

Figure 240 1. 2. 3.

Fuel to rail supply clamp assembly

Fuel to rail supply clamp assembly (2) High-pressure pump to rail tube assembly 1 High-pressure pump to rail tube assembly 2

NOTE: It is necessary to remove tube clamps (step 3) from high-pressure fuel pump to fuel rail assemblies if only one tube (tube 1 or 2) is to be removed. Tube clamps can remain installed if both pump to rail tubes are removed as an assembly. 3. Remove two clamps from high-pressure fuel pump to fuel rail tube assemblies 1 and 2.

Figure 239 1. 2.

Harness connector bracket

Harness 21-way connector bracket M8 x 16 bolt (3)

2. Remove three M8 x 16 bolts and harness 21-way connector bracket.

Figure 241

Crowfoot wrench (typical)

4. Obtain a crowfoot wrench (page 234) for removal of all high-pressure fuel lines. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

FUEL SYSTEM

203

6. Loosen line fitting nuts at fuel pump and fuel rail and remove high-pressure pump to rail tube assembly 1. Cap open fuel pump and fuel rail connections.

Figure 242 High-pressure pump to rail tube assembly 2 1. 2.

Line fitting nut at high-pressure fuel pump Line fitting nut at fuel rail

5. Loosen line fitting nuts at fuel pump and fuel rail and remove high-pressure pump to rail tube assembly 2. Cap open fuel pump and fuel rail connections with clean Disposable Air and Fuel Caps (page 234).


High-pressure rail to injector tube

Cylinder 1 high-pressure connector body and retaining nut Cylinder 1 high-pressure rail to injector tube assembly Fuel rail

7. Loosen injector 1 high-pressure rail to injector tube assembly fitting nuts at cylinder head and fuel rail.


Line fitting nut at high-pressure fuel pump Line fitting nut at fuel rail

Figure 245 Fuel cap on high-pressure connector body (typical) EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

FUEL SYSTEM

204

8. Remove and discard cylinder 1 high-pressure rail to injector tube assembly. Cap open high-pressure connector body and fuel rail connections with clean Disposable Air and Fuel Caps (page 234).

Figure 247

Figure 246 Cylinders 2-6 high-pressure rail to injector tubes

9. Remove high-pressure rail to injector tube assemblies for cylinders 2 through 6. Cap open high-pressure connector body and fuel rail connections.

Injector and Fuel Drain (Return) Lines NOTE: It is not necessary to disassemble the fuel drain lines unless individual components are leaking or damaged. CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed.

1. 2. 3. 4. 5. 6. 7.

Fuel drain (return) tube

Fuel rail 14.7 x 22 seal ring (4) M14 banjo bolt (2) Fuel drain tube M8 x 16 bolt and closed (P) clamp assembly Line fitting nut Fuel drain hose (hex manifold tee)

1. Remove M8 x 16 bolt and closed (P) clamp securing fuel drain tube to crankcase. 2. Loosen fuel drain line fitting nut at the fuel return hex manifold tee and disconnect tube from fuel return line. 3. Remove M14 banjo bolt and two 14.7 x 22 seal rings to disconnect fuel drain tube at fuel rail. Discard seal rings. 4. Remove M14 banjo bolt and 14.7 x 22 seal rings connecting fuel drain tube at cylinder head. Remove fuel drain tube and discard seal rings.


FUEL SYSTEM

205

CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed.

Fuel Rail

NOTE: Use Fuel Line Disconnect Tool 11.8 mm (page 234) to disconnect all low-pressure fuel line quick-connect fittings. a. Slide tool over release quick-connect fitting.

buttons

on

b. Pull quick-connect fitting to disconnect.

Figure 248 1. 2.

Fuel rail assembly

M8 x 40 bolt (3) Fuel rail

1. Support fuel rail to prevent it from falling during removal. 2. Remove three M8 x 40 bolts and remove fuel rail from cylinder head. Fuel Supply and Drain (Return) Lines

Figure 250 After-filter fuel supply hose connections 1. 2. 3. 4. 5.

Quick-connect 90° fitting (at high-pressure fuel pump) Quick-connect 90° fitting (at metering unit valve) M14 banjo bolt Clip After-filter fuel supply hose

1. Disconnect after-filter fuel supply hose assembly quick-connect 90° fittings at high-pressure fuel pump and metering unit valve assembly. Immediately cap openings using clean Disposable Air and Fuel Caps (page 234). Figure 249 (typical)


2. Remove M14 banjo bolt and 14.7 x 22 mm seal rings at fuel filter housing and remove after-filter fuel supply hose assembly. Discard seal rings.


FUEL SYSTEM

206

Figure 251 Pre-pump fuel supply hose connections 1. 2. 3.

Quick-connect 90° fitting (at high-pressure fuel pump) Quick-connect 90° fitting (at primer pump) Pre-filter fuel supply hose

3. Disconnect pre-pump fuel supply hose assembly quick-connect 90° fittings at high-pressure fuel pump and at primer pump. Remove hose and cap openings.

Figure 252 Pre-filter fuel supply hose connections 1. 2. 3.

Quick-connect 90° fitting (at high-pressure fuel pump) Quick-connect 90° fitting (at filter housing) Pre-filter fuel supply hose

4. Disconnect pre-filter fuel supply hose assembly quick-connect 90° fittings at high-pressure fuel pump and at fuel filter housing. Remove hose and cap openings.


FUEL SYSTEM

207

7. Disconnect 8 x 13 single retainers and remove fuel drain hose from engine.

Figure 253 1. 2. 3. 4. 5.

Fuel drain hose connections

Quick-connect 90° fitting (at high-pressure fuel pump) M6 x 16 bolt and closed (P) clamp Metering unit bracket Quick-connect 90° fitting (at filter housing) Fuel drain hose

5. Remove M6 x 16 bolt and closed (P) clamp attaching fuel drain hose to metering unit bracket. 6. Disconnect fuel drain hose assembly quick-connect 90° fittings at high-pressure fuel pump and at fuel filter housing. Cap openings.

Figure 255 1. 2. 3.

Fuel primer pump

Fuel primer pump assembly M8 x 25 bolt (2) Fuel filter housing

NOTE: The fuel primer pump can be removed as an assembly along with the fuel filter housing. If the primer pump is to be replaced, remove two M8 x 25 bolts and remove pump assembly from filter housing. 8. Remove two M8 x 25 bolts. 9. Remove fuel primer pump from fuel filter housing.

Figure 254 1. 2. 3.

Fuel drain hose retainers

Fuel drain hose Fuel filter bracket 8 x 13 single retainer (2) EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

FUEL SYSTEM

208 Fuel Filter Housing Assembly

Figure 256 1. 2.

2. Remove three M8 x 45 bolts and remove fuel filter housing assembly.

Metering unit bracket

M8 x 16 bolts (3) Metering unit bracket

1. Remove three M8 x 16 bolts and remove metering unit bracket.

Figure 258 1. 2. 3.

Fuel filter bracket assembly

9 ID x 18 OD x 10.5 spacer (3) M8 x 30 bolt (4) 9 ID x 17 OD x 6.5 spacer

3. Remove four M8 x 30 bolts and spacers; remove fuel filter bracket from crankcase.

Fuel Filter Stand Pipe Replacement If diagnostic testing indicated replacement of the fuel filter stand pipe, remove the stand pipe and replace with new following this procedure.

Figure 257 1. 2.


Fuel filter housing assembly M8 x 45 bolt (3)


FUEL SYSTEM

209

7. Apply P-80® rubber lubricant or equivalent (page 234) to filter cap o-ring and place in position in housing O-ring groove. 8. Insert new filter element in filter housing. 9. Install filter cap and tighten to special torque (page 233).

High-pressure Pump (Drive Belt) Pulley

Figure 259 1. 2. 3. 4. 5. 6.

Fuel Filter Stand Pipe

Stand pipe O-ring Stand pipe Fuel filter housing Fuel filter cap Fuel filter cap O-ring Fuel filter element

1. Remove fuel filter cap and O-ring 2. Using an appropriate wrench, loosen and remove stand pipe from housing. 3. Remove O-ring from center tube at bottom of stand pipe

Figure 260 1. 2.

High-pressure pump pulley

High-pressure pump pulley M16 x 40 LH bolt (left-hand thread)

4. Apply P-80® rubber lubricant or equivalent (page 234) to new O-ring and install O-ring on center tube in bore at bottom of stand pipe.

1. Remove M16 x 40 LH bolt. Clean any sealer off of bolt threads.

5. Insert stand pipe into housing assembly and using carefully thread pipe into bore at bottom of housing.

2. Remove high-pressure pump pulley from drive belt shaft assembly. Clean any sealer from shaft and pulley.

6. Tighten the stand pipe to special torque (page 233).


FUEL SYSTEM

210

High-pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal

6. Clean all RTV from sealing surfaces. 7. Remove drive belt shaft from high-pressure fuel pump drive housing. 8. Remove and discard drive belt shaft 30.2 x 3 O-ring.

High-pressure Fuel Pump (HPFP) and Drive Housing NOTE: The high-pressure fuel pump and drive housing can be removed as an assembly without removing the fuel filter assembly.

Figure 261 and seal 1. 2. 3. 4. 5.

High-pressure pump pulley housing

High-pressure pump pulley housing M10 x 40 bolt (4) 30.2 x 3 O-ring 55 x 70 x 8 radial shaft seal Drive belt shaft

1. With an awl and hammer, punch two holes 180° apart in radial shaft seal. 2. Thread a slide hammer (page 234) with correct size screw into one of the two holes. 3. Slide hammer until one side of seal begins to pull out of housing. Move slide hammer to other hole and repeat until radial shaft seal is removed. 4. Remove four M10 x 40 drive belt pulley housing bolts. 5. Remove drive belt pulley housing assembly off high-pressure fuel pump drive housing. Check that (alignment) sleeve remains in place on pulley housing mounting flange.

Figure 262 bracket 1. 2. 3. 4.

High-pressure fuel pump support

High-pressure fuel pump M12 x 30 bolt (2) Support bracket M14 x 30 bolt (2)

1. Remove two M12 x 30 and two M14 x 30 bolts and remove support bracket from below high-pressure fuel pump.


FUEL SYSTEM

Figure 263 High-pressure fuel pump drive housing and jam nut 1. 2. 3. 4.

High-pressure pump gear High-pressure fuel pump drive housing 25 x 44 x 4 washer M24 jam nut

NOTE: If high-pressure fuel pump is to be removed from drive housing after removal of assembly from engine, block crankshaft to prevent timing gears from turning and loosen (but do not remove) M24 jam nut before proceeding with next step. This will aid removal of pump from drive housing for later service.

Figure 264 housing 1. 2. 3. 4. 5. 6. 7.

211

High-pressure fuel pump and drive

High-pressure fuel pump drive housing M12 x 90 bolt M12 x 130 bolt (2) High-pressure fuel pump 16.7 x 24 seal ring (4) Quick-connect M16 x 1.5 connector (4) M12 x 40 bolt

2. Remove M12 x 40, M12 x 90 and two M12 x 130 bolts and remove high-pressure fuel pump and drive housing assembly from crankcase.

Figure 265 1. 2. 3.

Dowel pin and sleeve

M10 x 40 bolt (4) Dowel pin Sleeve


FUEL SYSTEM

212

3. Check that dowel pin and sleeve remain seated in drive housing.

NOTE: The injector harness nuts are part of the injector harness and cannot be separated.

NOTE: If high-pressure fuel pump is to be replaced, continue with steps 4 through 6 to remove pump from drive housing.

1. Loosen 12 injector harness nuts and position injector harness aside.

4. Remove 25 x 44 x 4 washer and M24 jam nut securing pump gear to pump shaft. 5. Remove four M10 x 40 bolts attaching high-pressure fuel pump to drive housing. 6. Remove four M16 x 1.5 quick-connect connectors and discard seal rings.

Fuel Injectors CAUTION: To prevent engine damage, remove injectors before removing cylinder head. CAUTION: To prevent engine damage, do not use power tools to remove or install fuel injector clamp bolts. Threads will be damaged if a bolt or nut is rotated too quickly. CAUTION: To prevent engine damage, install new injector O-ring and combustion washer before installing injector.

Figure 267 (typical) 1. 2.

High-pressure connector body

Retaining high-pressure connector nut (6) High-pressure connector body (6)

2. Remove six retaining high-pressure connector nuts. 3. Remove and discard six high-pressure connector bodies. 4. Cover cylinder head high-pressure connector body bores with appropriate size plugs from Disposable Air and Fuel Caps (page 234).

Figure 266 1. 2.

Fuel injector connections

Injector harness nuts (12) Engine injector harness


FUEL SYSTEM

213

7. Use Injector Puller (page 234) to remove injectors.

Figure 268 1. 2. 3.

Injector hold-down clamp

M8 x 50 bolt (6) and rounded washer (6) Injector hold-down clamp (6) Thrust washer (6)

5. Remove six M8 x 50 hold-down clamp bolts and rounded washers.

Figure 270 1. 2.

Injector extractor (typical)

Extractor (part of Injector Puller) Injector

8. Install extractor on injector.

6. Remove six thrust washers.

Figure 271 (typical) Figure 269 1. 2. 3. 4. 5. 6. 7.

Injector Puller

Clamping sleeve Extractor plate Extractor Knurled nut Extractor nut Plate column (2) Plate column nuts (2)

1. 2.

Clamping sleeve on extractor

Extractor Clamping sleeve

9. Slide clamping sleeve over extractor.


FUEL SYSTEM

214

12. Install knurled nut and extractor nut, with the extractor nut backed out. 13. Hold knurled nut and tighten extractor nut to remove injector, combustion washer and hold-down clamp. NOTE: Make sure that no combustion washer remains in the injector bore after the injector is removed. 14. Cover cylinder head injector bore with appropriate size plugs from Disposable Air and Fuel Caps (page 234).


Extractor plate and plate columns

Extractor plate Plate column (2)

10. Position two plate columns on two opposite cylinder head bolts, and slide extractor plate over extractor and plate columns. 11. Install and finger-tighten plate column nuts on plate columns. Figure 274 1. 2. 3.

Injector seals (typical)

Injector assembly 3 x 20.9 ID O-ring Combustion washer

15. Using a small non-metallic hand tool, carefully remove and discard combustion washer and O-ring. Wipe injector nozzle with a lint-free cloth. CAUTION: To prevent engine damage, do not clean fuel injectors with parts solvent or other chemicals. 16. Clean injector tip with Fuel Injector Tip Cleaning Brush (page 234). Figure 273 1. 2.

Extractor nut (typical)

17. Insert injector into Fuel Injector Cup (page 234), and place in Fuel Injector Rack Holder (page 234).

Knurled nut Extractor nut


FUEL SYSTEM

215

Cleaning and Inspection

Fuel Injector Bore

Low-pressure and High-pressure Fuel System Components

1. Use Injector Sleeve Brushes (page 234) in injector bore to remove deposits.

1. Inspect low-pressure fuel lines for kinks, obstructions or other damage. Replace if necessary. 2. Inspect low-pressure fuel line quick-connect fitting O-ring seals for damage. Replace low-pressure fuel lines if necessary. 3. Inspect fuel filter housing assembly and fuel primer pump assembly for damage. Replace if necessary. 4. Inspect high-pressure pump input shaft and driving sleeve splines for wear or damage. Replace if necessary. WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 2. Use filtered compressed air to clean out debris from injector bores.

Fuel Injector Harness Inspect injector wiring harness for kinked wires or terminals. Replace harness if kinks are found. Kinked wires can result in oil leaking in between the harness protective foam covering and the wires.

5. Clean outside surfaces of low-pressure fuel lines, fuel filter housing assembly and fuel primer pump assembly with a suitable non-caustic solvent. Dry with filtered compressed air.


FUEL SYSTEM

216

Installation Fuel Injectors CAUTION: To prevent engine damage, remove protective plugs and cups only before immediate installation of components. CAUTION: To prevent engine damage, do not use power tools to remove or install fuel injector clamp bolts. Threads will be damaged if a bolt or nut is rotated too quickly.

Figure 276 1. 2. 3.

Injector seals (typical)

Injector assembly 3 x 20.9 ID O-ring Combustion washer

CAUTION: To prevent engine damage, install new injector O-ring and combustion washer before installing injector. 2. Install a new combustion washer onto injector tip. Figure 275

Thrust washer

3. Lubricate a new 3 x 20.9 ID O-ring with clean engine oil and install in recess at mid-point of injector.

1. Install six thrust washers on cylinder head.

Figure 277 Injector and injector hold-down clamp orientation (typical) 1. 2.

Injector hold-down clamp Injector fuel inlet opening


FUEL SYSTEM

4. Slide injector into hold-down clamp with injector fuel inlet opening on opposite side of hold-down clamp.

217

6. Using Injector Installer (page 234), firmly press injector and hold-down clamp and make sure injector is fully seated into cylinder head. CAUTION: To prevent engine damage, six new high-pressure connector bodies must be installed and aligned before tightening M8 x 50 bolts for six fuel injectors.

Figure 278 Injector and injector hold-down clamp installation (typical) 1. 2.

Injector hold-down clamp Injector

Figure 279 Alignment of high-pressure connector body (typical) CAUTION: To prevent engine damage, align injector and hold-down clamp correctly with cylinder head; do not twist injector when inserting injector into cylinder head. NOTE: Make sure injector bore in cylinder head is clean and no old combustion washer remains inside the bore. 5. Install injector by lowering injector and hold-down clamp as one unit into injector bore.

1. 2. 3.

Notch in cylinder head Locating ball High-pressure connector body

7. Align locating ball on each new high-pressure connector body with notch in cylinder head and install six new high-pressure connector bodies.


FUEL SYSTEM

218 Injector hold-down clamp (M8 x 50 bolts)

High-pressure connector body (retaining nuts)

Figure 280

Figure 281 (typical)

1. 2. 3.

Injector hold-down clamp bolt


8. Install six rounded washers and M8 x 50 bolts finger tight.

1. 2.


High-pressure connector retaining nut (6) High-pressure connector body (6)

9. Install six high-pressure connector retaining nuts and tighten nuts to 55 N·m (41 lbf·ft). 10. Completely loosen six high-pressure retaining nuts; then, retighten nuts to 10 N·m (89 lbf·in).


FUEL SYSTEM

219

Injector hold-down clamp (Final torque of M8 x 50 bolts)

High-pressure connector body (Final torque of retaining nuts)

Figure 282

Figure 283 (typical)

1. 2. 3.

Injector hold-down clamp bolt


11. Tighten six M8 x 50 injector hold-down clamp bolts to 25 N·m (18 lbf·ft). 12. Tighten six M8 x 50 injector hold-down clamp bolts an additional 90°.

1. 2.


High-pressure connector retaining nut (6) High-pressure connector body (6)

13. Tighten six high-pressure connector retaining nuts to 20 N·m (15 lbf·ft). 14. Tighten six high-pressure connector retaining nuts an additional 32°.


FUEL SYSTEM

220

CAUTION: To prevent engine damage, hold injector harness terminals to prevent twisting or turning while tightening the injector harness nuts. Kinked harness terminals can result in an oil leak path between the protective cover and the wire. CAUTION: To prevent engine damage, use a torque wrench to tighten injector harness nuts to 1.5 N·m (13 lbf·in). 15. Connect injector harness to injectors. Make sure harness terminals are in straight alignment with harness. Hold terminals stationary to avoid twisting and tighten nuts to special torque (page 233). Figure 284 1. 2.

Injector connections

Injector harness nuts (12) Engine injector harness


FUEL SYSTEM

221

High-pressure Fuel Pump (HPFP) and Drive Housing

Figure 285 1. 2. 3. 4.

High-pressure fuel pump and drive housing assembly

High-pressure fuel pump M10 x 40 bolts (4) Key Dowel pin

5. 6. 7. 8.

Drive housing 25 x 44 x 4 washer M24 jam nut Sleeve

9. High-pressure pump gear 10. 100 x 3.349 O-ring

1. Press key into slot on high-pressure fuel pump shaft.

4. Install four M10 x 40 bolts, hand-tight, to attach high-pressure fuel pump to drive housing.

2. Install a new 100 x 3.349 O-ring on fuel pump mounting flange collar.

5. Install 25 x 44 x 4 washer and M24 jam nut, hand-tight, to secure gear on high-pressure fuel pump shaft.

3. Place high-pressure fuel pump gear into pump drive housing and assemble drive housing to pump. Check that key slot in gear is aligned with key on shaft and push gear onto shaft.


FUEL SYSTEM

222

CAUTION: Install components and tighten bolts within five minutes of Wacker® A-442 RTV sealant or equivalent application. 7. Apply Wacker® A-442 RTV sealant (page 234) or equivalent to mating surfaces of drive housing and crankcase. 8. Position high-pressure fuel pump and drive housing assembly on crankcase using care to align pump drive gear with idler gear. Install M12 x 40, M12 x 90 and two M12 x 130 bolts and tighten bolts to special torque (page 233).

Figure 286 1. 2. 3.

Dowel pin and sleeve placement

9. Final tighten four M10 x 40 bolts to special torque (page 233) to secure high-pressure fuel pump to drive pump housing.

M10 x 40 bolt (4) Dowel pin Sleeve

6. Check that dowel pin and sleeve are properly seated in place in drive housing.

Figure 288 gear 1. 2. 3. 4.

Figure 287 housing 1. 2. 3. 4. 5. 6. 7.


High-pressure (fuel) pump gear High-pressure fuel pump drive housing 25 x 44 x 4 washer M24 jam nut


Drive housing M12 x 90 bolt M12 x 130 bolt (2) High-pressure fuel pump 16.7 x 24 seal ring Quick-connect M16 x 1.5 connector M12 x 40 bolt

10. Block crankshaft to prevent timing gears from turning and final tighten M24 jam nut to special torque (page 233).


FUEL SYSTEM

223

High-Pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal

Figure 289 High-pressure fuel pump and support (bracket) 1. 2. 3. 4.

High-pressure fuel pump M12 x 30 bolt (2) Support (bracket) M14 x 30 bolt (2)

11. Place support bracket in position below high-pressure fuel pump and install two M12 x 30 and two M14 x 30 bolts. •

Tighten two M12 x 30 bolts to standard torque (page 471).

•

Tighten two M14 x 30 bolts to special torque (page 233).

NOTE: If high-pressure fuel pump was replaced or fittings were previously removed, continue with step 12. Install four M16 x 1.5 quick-connect connectors with new 16.7 x 24 seal rings to high-pressure fuel pump. Tighten connectors to special torque (page 233).

Figure 290 and seal 1. 2. 3. 4. 5.

High-pressure pump pulley housing

High-pressure pump pulley housing M10 x 40 bolt (4) 30.2 x 3 O-ring 55 x 70 x 8 radial shaft seal Drive belt shaft

1. Lubricate drive belt shaft with clean engine oil and insert shaft into high-pressure pump pulley housing bushing bore. 2. Install new 30.2 x 3 O-ring in groove on drive belt shaft. 3. Check that (alignment) sleeve is in place on pulley housing mounting flange. CAUTION: To prevent engine damage, install component within 5 minutes of sealant application to inhibit the formation of a skin and ensure a leak proof joint. 4. Apply Wacker® A-442 RTV sealant (page 234) or equivalent to joining surfaces of pulley housing and high-pressure fuel pump drive housing. 5. Place pulley housing assembly with drive belt shaft in position on high-pressure fuel pump drive housing, using care to mesh drive belt shaft gear with idler gear in crankcase.


FUEL SYSTEM

224

6. Install four M10 x 40 bolts and tighten to special torque (page 233).

Fuel Filter Housing Assembly

7. Using Fan Hub/High Pressure Drive Seal Installer (page 234), drive new radial shaft seal into housing. Seal is fully installed when tool bottoms out on housing.

High-Pressure Pump (Drive Belt) Pulley

Figure 292 1. 2. 3.

Figure 291 1. 2.

Fuel filter bracket assembly

9 ID x 18 OD x 10.5 spacer (3) M8 x 30 bolt (4) 9 ID x 17 OD x 6.5 spacer

High-pressure pump pulley

High-pressure pump pulley M16 x 40 LH bolt (left-hand thread)

1. If removed, position fuel filter bracket assembly with brace on crankcase and install four M8 x 30 bolts and spacers. Tighten bolts to special torque (page 233).

1. Install high-pressure pump pulley onto drive belt shaft. 2. Install M16 x 40 LH bolt. Tighten bolt to special torque (page 233).

Figure 293 1. 2.


Fuel filter housing assembly M8 x 45 bolts (3)


FUEL SYSTEM

2. Install fuel filter housing assembly and three M8 x 45 bolts. Tighten bolts to special torque (page 233).

Fuel Primer Pump Assembly


Metering unit (valve) bracket (typical)

M8 x 16 bolts (3) Metering unit (valve) bracket

3. Position metering unit bracket on filter housing and install three M8 x 16 bolts. Tighten bolts to standard torque (page 471).

225

1. 2. 3. 4. 5. 6. 7. 8.

Fuel primer pump assembly

Check valve Threaded union 14.7 x 22 seal ring (3) Fuel primer pump M8 x 25 bolt (2) Fuel filter housing Banjo fitting Fuel supply adapter

1. If removed from fuel filter housing, install primer pump assembly and two M8 x 25 bolts. Tighten bolts to special torque (page 233). NOTE: If fuel primer pump assembly was replaced or fittings were previously removed, continue with step 2. 2. Install banjo fitting with two new 14.7 x 22 seal rings and fuel supply adapter in primer pump inlet port. Tighten adapter to special torque (page 233). 3. Install check valve on banjo fitting. Tighten check valve to special torque (page 233) and install dust cap. 4. Install threaded union and 14.7 x 22 seal ring in primer pump outlet port. Tighten threaded union to special torque (page 233).


FUEL SYSTEM

226 Fuel Supply and Drain (Return) Lines


Fuel drain hose retainers (typical)

Fuel drain hose Fuel filter bracket 8-13 single retainer (2)

1. Check that O-rings are in place in fuel drain quick-connect 90° fittings and not damaged. Replace as necessary. 2. Place fuel drain hose in position at bottom of fuel filter bracket and attach to bracket with two 8-13 single retainers.

1. 2. 3. 4. 5.

Fuel drain hose connections

Quick-connect 90° fitting (at high-pressure fuel pump) M6 x 16 bolt and closed (P) clamp Metering unit (valve) bracket Quick-connect 90° fitting (at filter housing) Fuel drain hose

3. Connect fuel drain hose to high-pressure fuel pump by pushing on quick-connect fitting until an audible click is heard. Pull quick-connect fitting to make sure it is seated. 4. Connect fuel drain hose to fuel filter housing by pushing on quick-connect fitting until an audible click is heard. Pull quick-connect fitting to make sure it is seated. 5. Install closed (P) clamp and M6 x 16 bolt to attach end fitting of fuel drain hose from hex manifold tee to metering unit bracket. Tighten bolt to standard torque (page 471). 6. Cap unconnected end of hex manifold tee using Disposable Air and Fuel Caps (page 234), to prevent dirt from entering fuel system until final connection with injector and fuel rail drain tube is made.


FUEL SYSTEM

Figure 298 1. 2. 3.

Pre-filter fuel supply hose assembly

Quick-connect 90° fitting (at high-pressure fuel pump) Quick-connect 90° fitting (at filter housing) Pre-filter fuel supply hose

Figure 299 1. 2. 3.

227

Pre-pump fuel supply hose assembly

Quick-connect 90° fitting (at high-pressure fuel pump) Quick-connect 90° fitting (at primer pump) Pre-pump fuel supply hose

7. Check that O-rings are in place in pre-filter fuel supply quick-connect 90° fittings and not damaged. Replace as necessary.

9. Check that O-rings are in place in pre-pump fuel supply hose quick-connect 90° fittings and not damaged. Replace as necessary.

8. Install pre-filter fuel supply hose. Push on quick-connect 90° fitting at high-pressure fuel pump until an audible click is heard. Pull quick-connect fitting to make sure it is seated. Repeat the procedure for the quick-connect 90° fitting at fuel filter housing.

10. Install pre-pump fuel supply hose. Push on quick-connect 90° fitting at high-pressure fuel pump until an audible click is heard. Pull quick-connect fitting to make sure it is seated. Repeat the procedure for the quick-connect 90° fitting at primer pump.


FUEL SYSTEM

228

d. Install C-clip between after filter fuel supply hose and fuel drain hose. e. Cap quick-connect 90° connector to fuel metering valve assembly to prevent dirt from entering fuel system until final connection to metering valve can be made.

Fuel Rail

Figure 300 After-filter fuel supply hose connections 1. 2. 3. 4. 5.

Quick-connect 90° fitting (at high-pressure fuel pump) Quick-connect 90° fitting (at metering unit) M 14 banjo bolt with two 14.7 x 22 seal rings C-clip After-filter fuel supply hose

Figure 301 11. Install after-filter fuel supply hose as follows: a. Check that O-rings are in place in after-filter fuel supply hose quick-connect 90° fittings and not damaged. Replace as necessary. b. Position banjo fitting with two new 14.7 x 22 seal rings at filter housing and install M14 banjo bolt. Tighten banjo bolt to special torque (page 233). c.

1. 2.

Fuel rail assembly


1. Support fuel rail in position against underside of cylinder head. 2. Install and hand tighten three M8 x 40 bolts to attach rail to cylinder head.

Push on quick-connect 90° fitting at high-pressure pump until an audible click is heard. Pull quick-connect fitting to make sure it is seated.


FUEL SYSTEM Injector and Fuel Drain (Return) Lines

229

4. Tighten fuel drain tube M14 banjo bolts at fuel rail and cylinder head to special torque (page 233). 5. Install closed (P) clamp and M8 x 16 bolt to secure drain tube to crankcase. Tighten bolt to standard torque (page 471).

High-pressure Fuel Lines

Figure 302 1. 2. 3. 4. 5. 6. 7.

Fuel drain tube connections

Fuel rail 14.7 x 22 seal ring (4) M14 banjo bolt (2) Fuel drain tube M8 x 16 bolt and closed (P) clamp assembly Line fitting nut Fuel drain hose (hex manifold tee)

1. Install M14 banjo bolt with two new 14.7 x 22 seal rings to connect fuel drain tube to cylinder head. Do not tighten at this time. 2. Install M14 banjo bolt with two new 14.7 x 22 seal rings to connect fuel drain tube to fuel rail. Do not tighten at this time. NOTE: Use a backup wrench when tightening fitting nut on hex manifold tee.

Figure 303

Crowfoot wrench (typical)

1. Obtain a crowfoot wrench (page 234) to connect all high pressure fuel line fittings. When using a crowfoot wrench to tighten fittings, calculate the torque compensation to match specific wrench configuration. See Using a Torque Wrench Extension (page 472) WARNING: To prevent personal injury or death, whenever any fuel line (tubing) in the high-pressure fuel system is removed, it must be replaced with new.

3. Connect fuel drain tube to fuel return hex manifold tee at fuel filter bracket. Tighten drain line fitting nut to special torque (page 233).


FUEL SYSTEM

230

3. Repeat step 2 to install new high-pressure rail to injector tube assemblies for cylinders 2 through 6.

Figure 304 Cylinder 1 high-pressure rail to injector tube assembly 1. 2. 3.

Cylinder 1 high-pressure connector body and retaining nut Cylinder 1 high-pressure rail to injector tube assembly Fuel rail

Figure 306 1. 2.

Fuel rail assembly


Fuel rail assembly (M8 x 40 bolts) 2. Install new high-pressure rail to injector tube assembly for cylinder 1 between fuel rail and cylinder head. Hand tighten line fitting nut at fuel rail and high-pressure connector body.

4. Tighten three M8 x 40 bolts to 35 N·m (26 lbf·ft). High-pressure rail to injector tube assemblies (fittings) 5. Tighten fittings (cylinders 1–6) to 23 N·m (17 lbf·ft). 6. Tighten fittings, an additional 60°.

Figure 305 tubes

Cylinders 2-6 high-pressure fuel


FUEL SYSTEM

231

8. Install new high-pressure pump to rail tube assembly 2 between high-pressure fuel pump and fuel rail. Tighten line fitting nuts.


Line fitting nut (at high-pressure fuel pump) Line fitting nut (at fuel rail)

7. Install new high-pressure pump to rail tube assembly 1 between high-pressure fuel pump and fuel rail. Hand tighten line fitting nuts.

Figure 309 1. 2. 3.

Fuel to rail supply clamp assembly

Fuel to rail supply clamp assembly (2) High-pressure pump to rail tube assembly 1 High-pressure pump to rail tube assembly 2

High-pressure pump to rail tube assemblies (fittings) 9. Tighten fittings to 23 N·m (17 lbf·ft). 10. Tighten fittings, an additional 60°. Fuel to rail supply clamps 11. Install two closed (P) clamps to tie high-pressure pump to rail tube assemblies 1 and 2 together. Tighten clamp screws securely.

Figure 308 High-pressure (fuel) pump to (fuel) rail tube assembly 2 1. 2.

Line fitting nut (at high-pressure fuel pump) Line fitting nut (at fuel rail)


FUEL SYSTEM

232

13. Connect air supply line to harness 21-way connector bracket.

Filter and Fuel Strainer Element Refer to MaxxForce® 11 and 13 Engine Operation and Maintenance Manual for filter element and fuel strainer element service procedures.

Fuel System Priming

Figure 310 1. 2.

Harness 21-way connector bracket

Harness 21-way connector bracket M8 x 16 bolt (3)

CAUTION: Before starting the engine for the first time after fuel system service, the fuel system must be primed to prevent severe damage to the HP fuel pump. Refer to Priming the Fuel System in the "ENGINE OPERATION" section of the Engine Operation and Maintenance Manual before starting the engine after repairs are complete.

12. Install harness 21-way connector bracket and three M8 x 16 bolts. Tighten bolts to standard torque (page 471)


FUEL SYSTEM

233

Specifications Table 14

Fuel System

Fuel strainer filtration

300 microns

Fuel filter element filtration

3-5 microns


Fuel System

Banjo bolt, M14

30 N·m (22 lbf·ft)

Check valve

35 N·m (26 lbf·ft)

Fuel drain line fitting nut

26 N·m (19 lbf·ft)

Fuel filter bracket M8 x 30 bolt

35 N·m (26 lbf·ft)

Fuel filter housing assembly M8 x 45 bolt

35 N·m (26 lbf·ft)

Fuel filter cap

25 N·m (18 lbf·ft)

Fuel filter stand pipe

12 N·m (106 lbf·in)

Fuel primer pump M8 x 25 bolt

30 N·m (22 lbf·ft)

Fuel rail M8 x 40 bolt

35 N·m (26 lbf·ft)

Fuel strainer cover

10 N·m (89 lbf·in)

Fuel supply adapter

30 N·m (22 lbf·ft)

High-pressure connector (body) retaining nut High-pressure fuel pump drive housing M12 x 40, M12 x 90, M12 x 130 bolt High-pressure fuel pump M10 x 40 bolt

See tightening steps in procedure 105 N·m (77 lbf·ft) 62 N·m (46 lbf·ft)

High-pressure fuel pump M24 jam nut

285 N·m (210 lbf·ft)

High-pressure fuel pump support M14 x 30 bolt

172 N·m (126 lbf·ft)

High-pressure pump to rail tube assembly line fitting nuts

See tightening steps in procedure

High-pressure rail to injector line fitting nut


High-pressure pump pulley housing M10 x 40 bolt High-pressure pump pulley M16 x 40 LH bolt Injector harness nut Injector hold-down clamp M8 x 50 bolt

62 N·m (46 lbf·ft) 280 N·m (207 lbf·ft) 1.5 N·m (13 lbf·in) See tightening steps in procedure

Quick-connect M16 x 1.5 connector

30 N·m (22 lbf·ft)

Threaded unions (M14 x 1.5)

30 N·m (22 lbf·ft)


FUEL SYSTEM

234 Special Service Tools Table 16

Fuel System

Description

Tool Number

Crowfoot wrench

Obtain locally


ZTSE4891

Fan Hub/High Pressure Drive Seal Installer

ZTSE6066

Fuel Injector Cups

ZTSE4892

Fuel Injector Rack Holder

ZTSE4299B

Fuel Injector Tip Cleaning Brush

ZTSE4301


ZTSE4773

Injector Installer

ZTSE4777

Injector Puller

ZTSE4770

Injector Sleeve Brushes

ZTSE4751

P80® Rubber Lubricant or equivalent

Obtain locally

Wacker® A-442 RTV sealant or equivalent

Obtain locally

Slide hammer

Obtain locally


OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION

235

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239 Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239 Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243 Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243 Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 Oil Cooler Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 Extension Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246 Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248 Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250


236




237

Exploded Views

Figure 311 1. 2. 3. 4. 5. 6.

Oil module assembly

Clamp (spring) Oil centrifuge Filter cover M8 x 45 bolt (3) Oil module flange Extension tube (DMR20 x DN14)

7.

Extension tube (DMR37 x DN29) 8. Seal (formed) 9. Oil module assembly 10. Heater return tube assembly 11. Hose clamp (spring) 12. Tube clamp (2)

13. M6 x 16 bolt (2) 14. Tube clamp (2) 15. Open breather tube assembly



238

Figure 312 1. 2. 3. 4. 5. 6. 7.

Oil module

Oil centrifuge Open breather tube connection Filter cover O-ring seal Oil filter M8 x 45 bolt (3) Extension tube (DMR20 x DN14)

8. 9. 10. 11. 12. 13. 14.

Extension tube (DMR37 x DN29) Oil module flange Seal (formed) Oil module assembly Oil module gasket Oil cooler Oil cooler gasket (2)

15. 16. 17. 18. 19. 20. 21. 22.

M10 x 170 bolt M10 x 200 bolt (2) M10 x 80 bolt (7) M8 x 90 bolt (2) M10 x 110 bolt (3) M10 x 140 bolt M8 x 45 bolt (2) M6 socket head bolt (4)




239


Engine Electrical

•

Turbochargers

•

Fuel System

Oil Filter Cover and Filter

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set the parking brake, and block the wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. Figure 313 WARNING: To prevent personal injury or death, remove the ground cable from the negative terminal of the main battery before disconnecting or connecting electrical components. Always connect the ground cable last. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.

1. 2. 3. 4.

Oil filter cover

Filter cover O-ring seal Oil filter Oil module assembly

1. Place absorbent material under the engine and oil module assembly. 2. Unscrew oil filter cover from oil module using a 36mm wrench. 3. Rotate oil filter element slightly and remove oil filter from filter cover. 4. Remove and discard O-ring seal from exterior of oil filter cover. 5. Dispose of oil filter according to local regulations.



240

Oil Centrifuge

2. Remove four M6 socket head bolts from oil centrifuge base and remove oil centrifuge and base as an assembly. 3. Remove seal ring from oil centrifuge base. Discard ring if damaged or leaking.

Figure 314 1. 2. 3.

Open breather tube assembly

Open breather tube assembly Clamp (spring) Oil centrifuge outlet

1. Release spring clamp and disconnect open breather tube assembly from oil centrifuge outlet.

Figure 316 Oil module assembly oil passageways 1.

Oil module assembly

4. Inspect oil module assembly oil passageways. Clean any obstructions or dirt as necessary.

Figure 315 1. 2.

Oil centrifuge

Oil centrifuge M6 socket head bolt (4) EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION Oil Module Assembly

241

4. Remove hose clamp (spring type) securing heater return tube to open breather tube assembly. Remove open breather tube assembly. 5. Remove M6 x 16 bolt and pipe single cushioned clamp securing heater return tube to LPCAC. 6. Loosen tube nut securing heater return tube to straight fitting on water distribution housing. Remove heater return tube. CAUTION: To prevent engine damage, drain all coolant from the engine through the radiator when removing the oil module assembly. Coolant can enter the oil sump and contaminate the engine oil. Engine oil must be drained and replaced after oil module removal and installation, before the engine is started. 7. Drain coolant from engine through radiator.

Figure 317 Open breather tube and heater return tube 1. 2. 3. 4. 5. 6. 7.

Open breather tube assembly M6 x 16 bolt (3) Tube clamp (2) Tube clamp (2) (for hydrocarbon injector (HCI) coolant return tube assembly) Hose clamp (spring type) Heater return tube assembly Pipe single cushioned clamp

1. Remove two tube clamp M6 x 16 bolts securing open breather tube to low-pressure charge air cooler (LPCAC). 2. If not previously done, unclip two tube clamps securing HCI coolant return tube assembly to open breather tube assembly. CAUTION: To prevent engine damage, when manipulating the open breather tube assembly, do not create a severe bend to the elbow hose that connects the tube to the oil module centrifuge outlet. The hose can crack. 3. If not previously done, release hose clamp (spring type) securing HCI coolant return tube assembly and disconnect tube from open breather tube.

Figure 318 items) 1. 2.

Oil module assembly (non-servicable

Plug (with seal) Bottom cover

CAUTION: To prevent engine damage, do not remove oil module assembly plugs, seals or bottom cover to drain the coolant or oil. These parts are not serviceable.



242

10. Remove DMR20 x DN14 and DMR37 x DN29 extension tubes. Inspect for damage. Replace as necessary.

Figure 319 1. 2. 3. 4. 5.

Oil module flange

Extension tube (DMR20 x DN14) Extension tube (DMR37 x DN29) Oil module flange M8 x 45 bolt (3) Engine oil temperature sensor

8. If not previously done, disconnect engine oil temperature sensor connector. Remove engine oil temperature sensor from oil module flange if needed. See "ENGINE ELECTRICAL" for procedure. 9. Remove three M8 x 45 bolts then remove oil module flange by pulling away from cylinder head to disengage extension tubes. Discard the oil module flange seal (formed). CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surfaces.

Figure 320 1. 2. 3. 4.

Oil module assembly

M10 x 80 bolt (7) M10 x 170 bolt M10 x 110 bolt (3) M8 x 150 bolt location (from water pump) includes 9 x 16 x 15 spacer

11. Remove seven M10 x 80 bolts, three M10 x 110 bolts, M10 x 170 bolt, M8 x 150 bolt (from water pump into front side of oil module assembly) and 9 x 16 x 15 spacer (between oil module assembly and water distribution housing). 12. Remove oil module assembly and gasket from engine. Discard oil module assembly gasket.



243

Oil Cooler

Figure 323

Figure 321 1. 2. 3.

Oil cooler bolts

M8 x 45 bolt (2) M8 x 90 bolt (2) Oil module assembly

Oil cooler gaskets

3. Remove two oil cooler gaskets from oil module assembly. Discard gaskets. Oil Pressure Relief Valve NOTE: Perform this procedure if replacing oil pressure relief valve for oil pressure-related issues.

1. Remove two M8 x 45 and two M8 x 90 bolts.

Figure 322

Oil cooler

2. Remove oil cooler from oil module assembly.

Figure 324

Oil pressure relief valve

1. Remove oil pressure relief valve. inspect oil pressure relief valve. necessary.


Clean and Replace if


244

Cleaning, Inspection and Testing Oil Cooler

1. Install Engine Oil Cooler Pressure Test Plate (page 250) onto oil cooler.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).


CAUTION: To prevent engine damage, replace the oil cooler if an engine bearing fails. Bearing debris can not be removed from the oil cooler.

2. Attach an air pressure regulator (page 250) to Engine Oil Cooler Pressure Test Plate. Connect to compressed air supply and adjust air pressure to approximately 172 to 207 kPa (25 to 30 psi).

1. The oil cooler can be cleaned in solvent and dried with filtered compressed air. •

Clean oil cooler in suitable solvent.

•

Flush and drain oil cooler to remove any residue. Dry components with filtered compressed air.

Oil Cooler Leak Test

3. Immerse oil cooler in large container of clean water. 4. Inspect oil cooler and test plate for leaks. If test plate fittings leak, tighten fittings and continue looking for leaks. Air bubbles at any location from oil cooler indicate leaks. Replace oil cooler if leaking. 5. Dry oil cooler using filtered compressed air.

Extension Tubes 1. Wipe extension tubes clean and inspect for tears, cuts or other damage to sealing surfaces. Replace as necessary.

Oil Centrifuge 1. Clean the oil centrifuge and inspect for damage. Replace as necessary.

Figure 325 1. 2.

Engine oil cooler pressure test

Air pressure regulator Engine Oil Cooler Pressure Test Plate



Installation

245

Oil Cooler

Oil Pressure Relief Valve NOTE: Perform this procedure if oil pressure relief valve is removed.

Figure 327 1. 2. 3.

Figure 326

Oil cooler bolts

M8 x 45 bolt (2) M8 x 90 bolt (2) Oil module assembly


1. Install oil pressure relief valve. Tighten valve to special torque (page 250).

1. Install two M8 x 45 and two M8 x 90 bolts through oil module assembly.

Figure 328

Oil cooler gaskets

2. Install new oil cooler gaskets over threads of installed bolts.


246

Figure 329


Oil cooler installation

3. Install oil cooler over gaskets and into oil module. Hand-tighten bolts. NOTE: Ensure gaskets remain in place during cooler installation. Tighten two M8 x 45 and two M8 x 90 bolts to special torque (page 250).

Oil Module Assembly 1. Position new gasket onto oil module assembly.

Figure 330 1. 2. 3. 4.

Oil module assembly

M10 x 80 bolt (7) M10 x 170 bolt M10 x 110 bolt (3) M8 x 150 bolt location (from water pump) includes 9 x 16 x 15 spacer

CAUTION: To prevent engine damage, do not use any silicone or other sealant when installing oil module assembly. 2. Position oil module assembly and install seven M10 x 80 bolts, M10 x 170 bolt and three M10 x 110 bolts. 3. Tighten oil module bolts to special torque (page 250). 4. Place 9 x 16 x 15 spacer between water distribution housing and oil module assembly. 5. Install M8 x 150 bolt through water pump assembly, water distribution housing, spacer and into front side of oil module assembly. Tighten M8 x 150 bolt to special torque (page 250).



Figure 331 1. 2. 3. 4. 5.

Oil module flange

Extension tube (DMR20 x DN14) Extension tube (DMR37 x DN29) Oil module flange M8 x 45 bolt (3) Engine oil temperature sensor

6. Lubricate sealing surfaces of DMR20 x DN14 and DMR37 x DN29 extension tubes with P-80® rubber lubricant or equivalent (page 250) and insert into oil module flange. 7. Install extension tubes into oil module flange using Extension Tube Installer Large and Extension Tube Installer Small (page 250). 8. Position oil module with new formed seal onto oil module while gently pushing extension tubes into cylinder head. Install three M8 x 45 bolts. Tighten bolts to special torque (page 250). 9. If not previously done, install engine oil temperature sensor into oil module flange if needed. See "ENGINE ELECTRICAL" for procedure. Connect temperature sensor electrical connector.

247

Figure 332 Open breather tube and heater return tube 1. 2. 3. 4. 5. 6. 7.

Open breather tube assembly M6 x 16 bolt (3) Tube clamp (2) Tube clamp (2) (for HCI coolant return tube assembly) Hose clamp (spring type) Heater return tube assembly Pipe single cushioned clamp

10. Install two tube clamps onto open breather tube. Position open breather tube assembly to LPCAC and install two M6 x 16 bolts. Tighten bolts to special torque (page 250). 11. If not previously done, snap two tube clamps over open breather tube assembly and HCI coolant return tube assembly. 12. If not previously done, install HCI coolant return tube onto open breather tube assembly and install hose clamp (spring type). See "AFTERTREATMENT SYSTEM" for procedure. 13. Position heater return tube assembly to straight fitting on water distribution housing and loosely tighten tube nut. 14. Install pipe single cushioned clamp onto heater return tube assembly and install M6 x 16 bolt into LPCAC and tighten to special torque (page 250).



248

15. Install heater return tube assembly hose onto open breather tube and install hose clamp (spring type). 16. Tighten heater return tube assembly tube nut to special torque (page 250).

Oil Centrifuge

Figure 334 1. 2. 3.

Open breather tube assembly

Open breather tube assembly Clamp (spring) Oil centrifuge outlet

3. Slide spring clamp over open breather tube assembly. Figure 333 1. 2.

Oil centrifuge

Oil centrifuge M6 socket head bolt (4)

1. Install centrifuge with base and new formed seal. Lubricate new formed seal with clean engine oil. 2. Install four M6 socket head bolts. Tighten bolts to standard torque (page 471).

4. Connect open breather centrifuge outlet.

tube

assembly

to

5. Install spring clamp and tighten.

Oil Filter Cover and Filter 1. Lubricate new O-ring with clean engine oil and install onto exterior of oil filter cover. 2. Install oil filter into oil filter cover.



249

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. CAUTION: To prevent engine damage, do not start or allow engine to run until first changing engine oil. 4. Drain and replace engine oil with recommended type and amount. See Engine Operation and Maintenance Manual for oil type, capacity and fill procedure. 5. Replace engine coolant with recommended type and amount. See Engine Operation and Maintenance Manual for coolant type, capacity and fill procedure. Figure 335 1. 2. 3. 4.

Oil filter cover

Filter cover O-ring seal Oil filter Oil module assembly

NOTE: Three additional bolts secure the oil module assembly. These bolts are installed along with the HP turbo air supply duct (two M10 x 200 bolts) and the air inlet duct for the LP turbocharger (one M10 x 140 bolt). See "TURBOCHARGERS" for procedures.

3. Install oil filter, O-ring seal and oil filter cover as an assembly into oil module. Tighten 36mm cover hex to special torque (page 250).


250



Oil Module Assembly

Heater return tube assembly bolt, M6 x 16

13 N·m (115 lbf·in)

Heater return tube assembly tube nut

11 N·m (97 lbf·in)

Oil cooler bolts, M8 x 45 and M8 x 90

25 N·m (18 lbf·ft)

Oil filter cover

40 N·m (30 lbf·ft)

Oil module assembly bolts, M10 x 80, M10 x 170 and M10 x 110

65 N·m (48 lbf·ft)

Oil module flange bolts, M8 x 45

24 N·m (18 lbf·ft)


40 N·m (30 lbf·ft)

Open breather tube assembly bolt, M6 x 16 Water pump bolt, M8 x 150 (front side of oil module)

13 N·m (115 lbf·in) 35 N·m (26 lbf·ft)


Oil Cooler

Description

Tool Number

Air pressure regulator

Obtain locally

Extension Tube Installer Large

ZTSE6051-1

Extension Tube Installer Small

ZTSE6051-2

Engine Oil Cooler Pressure Test Plate P-80® rubber lubricant or equivalent



EXHAUST GAS RECIRCULATION (EGR) SYSTEM

251

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 Coolant Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 Coolant Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 EGR Cooler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 Heat Protection (Cylinders 4-6) Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 EGR Outlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 EGR Inlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 Heat Protection EGR Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 EGR Dual Flap Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 EGR System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 EGR Cooler Assembly Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 In-vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 On Bench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 EGR Dual Flap Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 Heat Protection EGR Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 EGR Inlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 EGR Outlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 Heat Protection (Cylinders 4-6) Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268 EGR Cooler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268 Coolant Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269 Coolant Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270


252




253

Exploded Views

Figure 336 1. 2. 3. 4. 5.

EGR coolant manifold and elbow

Extension tube (DMR62 x 51) (2) Coolant manifold M18 O-ring boss plug Seal Coolant supply fitting (to hydrocarbon injector)

6.

Engine Coolant Temperature (ECT1) sensor 7. M8 x 45 bolt (2) 8. M8 x 50 x 16 stud bolt 9. Extension tube (DMR44 x 35) 10. Coolant elbow

11. Hydrocarbon injector fuel supply (tube) bracket 12. M8 x 25 bolt (3) 13. 60 x 3 O-ring 14. M8 x 12 bolt 15. M8 x 25 heat-resistant bolt



254

Figure 337 1. 2. 3.

EGR outlet tubes (cylinders 1-3 and cylinders 4-6)

EGR outlet gasket (4) M8 x 30 bolt (8) EGR outlet (cylinders 1-3) tube

4. 5.

EGR outlet (cylinders 4-6) tube Air intake throttle duct (horizontal)

6.

EGR module cover



Figure 338 1.

EGR inlet tube heat protection shield

M8 x 25 heat-resistant bolt (2)

2.

Heat protection (cylinders 4-6) shield

3.

M8 x 12 bolt (3)


255


256

Figure 339 1. 2. 3. 4. 5.

EGR system components

EGR dual flap valve EGR valve coolant return tube assembly M8 x 30 heat-resistant bolt (two at front of EGR valve) EGR cooler assembly EGR valve coolant supply tube assembly

6. 7. 8. 9. 10.

M10 x 170 bolt M8 x 25 heat-resistant bolt (2) EGR cooler bracket M8 x 25 heat-resistant bolt (2) Low-temperature EGR hose assembly 11. M10 x 45 bolt (6) 12. EGR dual flap valve gasket

13. 14. 15. 16. 17. 18. 19. 20.

M8 x 65 heat-resistant bolt (2) M8 x 12 bolt (3) Tube EGR gasket (4) M8 x 30 heat-resistant bolt (7) Inlet EGR (cylinders 1-3) tube Heat protection EGR shield Inlet EGR (cylinders 4-6) tube M8 x 25 heat-resistant bolt (6)



Removal

257

Coolant Manifold



Figure 340 1. 2. 3. 4. 5. 6. 7.

Coolant manifold

Extension tube (DMR44 x 35) M8 x 45 bolt (2) M8 x 12 bolt Extension tube (DMR62 x 51) M8 x 25 heat-resistant bolt M8 x 50 x 16 stud bolt Extension tube (DMR62 x 51)

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.

1. Remove M8 x 12 bolt securing heat protection EGR shield to coolant manifold.

NOTE: Refer to the following service sections for information on removal of components prior to this section.

3. Remove two M8 x 45 bolts, one M8 x 50 x 16 stud bolt and coolant manifold.

•

Engine Electrical

•

Front Cover, Fan Drive, Cooling System and Related Components

•

Turbochargers

•



2. Remove heat protection (cylinders 4-6) shield M8 x 25 heat-resistant bolt.

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface. 4. Remove two DMR62 x 51 and one DMR44 x 35 extension tubes. Pry the tubes out using a wood or plastic hammer handle or similar tool. Inspect extension tube sealing surfaces for damage. Replace as needed.



258 Coolant Elbow

EGR Cooler Bracket

Figure 341

Figure 342

1. 2. 3. 4.

Coolant elbow

M8 x 25 bolt (3) Coolant elbow Extension tube (DMR62 x 51) Hydrocarbon injector fuel supply (tube) bracket

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface.

1. 2. 3.

EGR cooler bracket

Heat protection shield (at front exhaust manifold) EGR cooler bracket M8 x 25 heat-resistant bolt (2)

1. Remove two M8 x 25 heat-resistant bolts from EGR cooler bracket and front exhaust manifold. Leave cooler bracket attached to EGR cooler.

1. Remove DMR62 x 51 extension tube from coolant elbow. Pry the tubes out using a wood or plastic hammer handle or similar tool. Inspect extension tube sealing surfaces for damage. Replace as needed. 2. Remove two lower M8 x 25 bolts and hydrocarbon injector fuel supply (tube) bracket. 3. Remove upper M8 x 25 bolt and coolant elbow. Remove and discard 60 x 3 O-ring.


EXHAUST GAS RECIRCULATION (EGR) SYSTEM Heat Protection (Cylinders 4-6) Shield

EGR Outlet Tubes



Heat protection (cylinders 4-6) shield M8 x 12 bolt (3) M8 x 25 heat-resistant bolt

259

1. 2. 3.

EGR outlet tubes

M8 x 30 bolt (8) EGR outlet (cylinders 1-3) tube EGR outlet (cylinders 4-6) tube

1. Remove four M8 x 30 bolts securing the EGR outlet (cylinders 4-6) tube. 1. Remove M8 x 25 heat-resistant bolt. 2. Remove three M8 x 12 bolts and heat protection shield.

2. Remove EGR outlet (cylinders 4-6) tube and discard tube gaskets. 3. Remove four M8 x 30 bolts securing the EGR outlet (cylinders 1-3) tube. 4. Remove EGR outlet (cylinders 1-3) tube and discard tube gaskets.



260 EGR Inlet Tubes

Figure 345 1. 2. 3.

EGR inlet (cylinders 1-3) tube

M8 x 25 heat-resistant bolt (4) EGR inlet (cylinders 1-3) tube Rear exhaust manifold

Figure 346 1. 2. 3. 4.


M8 x 25 heat-resistant bolt (2) EGR inlet (cylinders 4-6) tube Rear exhaust manifold M8 x 65 heat-resistant bolt (2)

1. Remove four M8 x 25 heat-resistant bolts. 2. Remove EGR inlet tube and two gaskets. Discard gaskets.

3. Remove two M8 x 25 heat-resistant bolts. 4. Remove two M8 x 65 heat-resistant bolts. 5. Remove EGR inlet (cylinders 4-6) tube and two tube gaskets. Discard gaskets.



261

Heat Protection EGR Shield


Heat protection EGR shield

Heat protection EGR shield M8 x 12 bolt (2)

1. Remove two M8 x 12 bolts at rear exhaust manifold. 2. Remove heat protection EGR shield.

EGR Dual Flap Valve

1. 2. 3. 4. 5.

EGR dual flap valve

EGR dual flap valve M8 x 30 heat-resistant bolt (9) EGR coolant supply tube nut Spring clamp Coolant return tube

NOTE: Drain coolant from EGR cooler assembly before removal. 1. Disconnect coolant return tube spring clamp and tube from EGR dual flap valve.

NOTE: If removing complete EGR cooler assembly for disassembly of engine, removal of EGR dual flap valve is not required.

2. Loosen tube nut and disconnect EGR dual flap valve coolant supply tube from bottom of EGR dual flap valve.

NOTE: The EGR dual flap valve can be removed as an in-vehicle service.

3. Remove nine M8 x 30 heat-resistant bolts (two bolts go through cooler into valve) and EGR dual flap valve. 4. Remove and discard EGR dual flap valve gasket.



262

EGR Cooler Assembly

1. Disconnect low-temperature EGR hose assembly spring clamp and hose from EGR cooler assembly. 2. Remove six M10 x 45 bolts, one M10 x 170 bolt and EGR cooler assembly. CAUTION: To prevent engine damage, do not disassemble the EGR cooler assembly. There are no serviceable parts inside the EGR cooler assembly. If the EGR cooler assembly is leaking or damaged, replace the EGR cooler assembly.

Figure 349 1. 2. 3. 4. 5. 6. 7.

EGR cooler assembly

EGR cooler assembly M10 x 45 bolt (6) M10 x 170 bolt Spring clamp Low-temperature EGR hose assembly Y-fitting (to deaeration port hoses) EGR cooler bracket

NOTE: Remove or disconnect exterior components (such as low temperature return hose at Y-fitting deaeration port hoses and EGR cooler bracket) from the EGR cooler for exchange with a replacement EGR cooler as needed. 3. Inspect EGR cooler assembly. damaged, replace the cooler.

If leaking or



Cleaning, Inspection and Testing EGR System Components

263

3. Install test plate from EGR Cooler Pressure Test Kit (page 270) to front of EGR cooler assembly. Tighten bolts to standard torque (page 471).

1. Using steam, clean all carbon from ends of EGR dual flap valve, coolant manifold and coolant elbow at rear. CAUTION: To prevent engine damage, do not use steam to clean EGR cooler heat exchanger cores. 2. Using steam, clean EGR cooler coolant return manifold at front. Clean all EGR cooler assembly coolant ports. 3. Inspect EGR system components for cracks and damage. Replace worn or damaged parts.

EGR Cooler Assembly Pressure Test In-vehicle 1. Remove EGR dual flap valve (page 261) from EGR cooler assembly. 2. Remove EGR outlet tubes (page 259) from EGR cooler assembly.

Figure 351 EGR cooler pressure test plate installed (EGR valve removed) 1. 2.

Pressure test plate M8 bolt (9)

4. Install test plate from EGR Cooler Pressure Test Kit (page 270) to rear of EGR cooler assembly. Tighten bolts to standard torque (page 471). WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 5. Attach the air pressure regulator and pressure gauge from EGR Cooler Pressure Test Kit (page 270) to pressure test plate. Connect to compressed air supply.

Figure 350 EGR cooler pressure test plate installed on EGR outlet ports 1. 2.

M8 bolt (4) Pressure test plate

NOTE: If detectable pressure loss is observed, recheck all test plate and EGR module assembly tightened connections. Make sure these connections are not the cause of pressure loss before replacing the EGR module assembly. 6. Pressurize EGR cooler assembly to 207 kPa (30 psi). Shut off the air supply and hold for 60 seconds. If detectable pressure loss is observed, replace EGR module (cooler) assembly (page



264

262). If no detectable pressure loss is observed, EGR module assembly is good. 7. Remove pressure test plates from front and rear of EGR cooler assembly.

On Bench

Figure 353 EGR cooler with pressure test plate installed on EGR outlet ports 1. 2.

Figure 352 EGR cooler pressure test plate installed (EGR valve removed) 1. 2.

Pressure test plate M8 bolt (9)

1. With EGR dual flap valve (page 261) removed, install pressure test plate from EGR Cooler Pressure Test Kit (page 270) to rear of EGR cooler assembly. Tighten bolts to standard torque (page 471).

M8 bolt (4) Pressure test plate

2. Install pressure test plate from EGR Cooler Pressure Test Kit (page 270) to front of EGR cooler assembly. Tighten bolts to standard torque (page 471). WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 3. Attach the air pressure regulator and pressure gauge from EGR Cooler Pressure Test Kit (page 270) to pressure test plate. Connect to shop air supply and adjust air pressure to a maximum pressure of 207 kPa (30 psi). 4. Completely submerge EGR cooler assembly in a large container of water. Inspect for air bubbles coming from coolant passages. 5. If bubbles are coming out of the EGR cooler assembly, replace EGR cooler assembly. If no leaks are found, reassemble EGR cooler assembly. 6. Remove pressure test plates from front and rear of EGR cooler assembly.



265

Installation EGR Cooler Assembly NOTE: Install or connect exterior components to the EGR cooler as necessary. When installing a replacement EGR cooler assembly, transfer necessary components from the cooler being replaced.

Figure 355 Figure 354 1. 2. 3. 4. 5.

EGR cooler assembly

EGR cooler assembly M10 x 45 bolt (6) M10 x 170 bolt Spring clamp Low-temperature EGR hose assembly

1. 2. 3. 4. 5.

EGR dual flap valve

EGR dual flap valve M8 x 30 heat-resistant bolt (9) EGR coolant supply tube nut Spring clamp Coolant return tube

1. Install a new gasket. 1. Install EGR cooler assembly, six M10 x 45 bolts and M10 x 170 bolt. Tighten bolts to special torque (page 270).

2. Install EGR dual flap valve and nine M8 x 30 heat-resistant bolts. Tighten bolts to special torque (page 270).

2. Connect low-temperature EGR hose assembly to EGR cooler assembly. Position and install spring clamp to secure hose.

3. Attach EGR valve coolant supply tube nut to EGR valve and tighten to special torque (page 270). 4. Attach EGR valve coolant return tube to EGR valve and install spring clamp.

EGR Dual Flap Valve NOTE: Complete this procedure only if the EGR dual flap valve was removed from EGR cooler assembly.



266

Heat Protection EGR Shield

EGR Inlet Tubes


Heat protection EGR shield

Heat protection EGR shield M8 x 12 bolt (2)

1. Install heat protection EGR shield and two M8 x 12 bolts at rear exhaust manifold. Tighten bolts to standard torque (page 471).

1. 2. 3. 4.


M8 x 25 heat-resistant bolt (2) EGR inlet (cylinders 4-6) tube Rear exhaust manifold M8 x 65 heat-resistant bolt (2)

1. Position two new EGR inlet (cylinders 4-6) tube gaskets, one to EGR valve and one to rear exhaust manifold. 2. Install EGR inlet (cylinders 4-6) tube, two M8 x 25 and two M8 x 65 heat-resistant bolts. standard torque (page 471).



267

EGR Outlet Tubes

Figure 358 1. 2. 3.


M8 x 25 heat-resistant bolt (4) EGR inlet (cylinders 1-3) tube Rear exhaust manifold

3. Position two new EGR inlet (cylinders 1-3) tube gaskets, one to EGR valve and one to middle exhaust manifold. 4. Install EGR inlet (cylinders 1-3) tube and four M8 x 25 heat-resistant bolts. Tighten bolts to special torque (page 270).

Figure 359 1. 2. 3.

EGR outlet tubes

M8 x 30 bolt (8) EGR outlet (cylinders 1-3) tube EGR outlet (cylinders 4-6) tube

1. Install EGR outlet (cylinders 4-6) tube, two new tube gaskets and four M8 x 30 bolts. Tighten bolts to standard torque (page 471). 2. Install EGR outlet (cylinders 1-3) tube, two new tube gaskets and four M8 x 30 bolts. Tighten bolts to standard torque (page 471). 3. Check EGR outlet tube hose clamps for looseness. Tighten tube hose clamps to special torque (page 270).



268

Heat Protection (Cylinders 4-6) Shield

Figure 360 1. 2. 3.


Heat protection (cylinders 4-6) shield M8 x 12 bolt (3) M8 x 25 heat-resistant bolt

1. Install heat protection shield and three M8 x 12 bolts. 2. Install M8 x 25 heat-resistant bolt.

EGR Cooler Bracket

Figure 361 1. 2. 3.

EGR cooler bracket

Heat protection shield (at front exhaust manifold) EGR cooler bracket M8 x 25 heat-resistant bolt (2)

1. Install two EGR cooler bracket M8 x 25 lower heat-resistant bolts. 2. Tighten bolts to standard torque (page 471).

3. Tighten heat protection shield bolts to standard torque (page 471).


EXHAUST GAS RECIRCULATION (EGR) SYSTEM Coolant Elbow

Coolant Manifold

Figure 363 Figure 362 1. 2. 3. 4.

Coolant elbow

M8 x 25 bolt (3) Coolant elbow Extension tube (DMR62 x 51) Hydrocarbon injector fuel supply (tube) bracket

1. Install new 60 x 3 O-ring. Install coolant elbow and loosely install upper M8 x 25 bolt. 2. Install HCI supply bracket and loosely install two lower M8 x 25 bolts. 3. Tighten three coolant elbow bolts to standard torque (page 471). 4. Lubricate sealing surfaces of extension tube (DMR62 x 51) with P-80® rubber lubricant or equivalent (page 270). Install extension tube (DMR62 x 51) to coolant elbow using Extension Tube Installer Large (page 270). NOTE: Alternatively, install extension tube (DMR62 x 51) into coolant manifold.

269

1. 2. 3. 4. 5. 6. 7.

Coolant manifold

Extension tube (DMR44 x 35) M8 x 45 bolt (2) M8 x 12 bolt Extension tube (DMR62 x 51) M8 x 25 heat-resistant bolt M8 x 50 x 16 stud bolt Extension tube (DMR62 x 51)

1. Lubricate two extension tubes (DMR62 x 51 and DMR44 x 35) sealing surfaces with P-80® rubber lubricant or equivalent (page 270). 2. Install extension tube (DMR62 x 51) and extension tube (DMR44 x 35) into coolant manifold using Extension Tube Installer Large and Extension Tube Installer Small (page 270). 3. Install coolant manifold using two M8 x 45 bolts, one M8 x 50 x 16 stud bolt and one M8 x 25 heat-resistant bolt (at heat protection (cylinder 4-6) shield). Tighten M8 x 12 heat-resistant bolt to standard torque (page 471). Tighten two M8 x 45 bolts and one M8 x 50 x 16 stud bolt to special torque (page 270). 4. Install one M8 x 12 bolt and tighten to standard torque (page 471).




EGR System

Coolant manifold, M8 x 45 bolt and M8 x 50 x 16 stud bolt

35 N·m (26 lbf·ft)

EGR dual flap valve, M8 x 30 heat-resistant bolt

24 N·m (18 lbf·ft)

EGR inlet (cylinders 4-6) tube, M8 x 25 heat-resistant bolt EGR inlet (cylinders 1-3) tube, M8 x 25 heat-resistant bolt EGR outlet tube hose clamps

24 N·m (18 lbf·ft)

EGR valve coolant supply tube nut

26 N·m (19 lbf·ft)

24 N·m (18 lbf·ft) 5 N·m (45 lbf·in)


EGR System

Description

Tool Number

EGR Cooler Pressure Test Kit

KL 20060 NAV


ZTSE6046


ZTSE6047


Obtain locally


AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

271

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 Air Intake Throttle Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277 Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 Air Intake Throttle Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 Manifold Warp Test for Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 Air Intake Throttle Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282


272




273

Exploded Views

Figure 364 1. 2. 3. 4.

Exhaust manifold

Sleeve spacer (18) M10 x 57 Torx® bolt (18) Multipiece oil (FEY) ring (4) Middle exhaust manifold

5. 6. 7. 8.

Front exhaust manifold M8 x 12 bolt Heat protection shield M10 x 45 stud

9.

Exhaust gas recirculation tube gasket (2) 10. Rear exhaust manifold 11. Exhaust manifold gasket (6)



274

Figure 365 1. 2. 3.

Air intake throttle horizontal duct

Air intake throttle horizontal duct Sensor O-ring Intake manifold pressure sensor

4. 5.

Charge air cooler outlet temperature sensor O-ring

6. 7. 8.

Cold start fuel ignitor (glow plug) M8 x 100 bolt (2) M8 x 50 bolt



Figure 366 1. 2. 3.

275

Air intake throttle vertical duct

Cold start fuel ignitor (glow plug) Intake manifold pressure sensor O-ring

4. 5.

Charge air cooler outlet temperature sensor Sensor O-ring

6. 7. 8.

Air intake throttle vertical duct M8 x 100 bolt (2) M8 x 50 bolt



276

Removal

Exhaust Manifold


1. Remove one M8 x 12 bolt that secures the heat protection shield to the front exhaust manifold and remove heat protection shield. CAUTION: To prevent engine damage, do not reuse sleeve spacers or exhaust manifold bolts.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. NOTE: Refer to the following service sections for information on removal of components prior to this section. •

Engine Electrical

•

Cold Start Assist

•


•


•

Turbochargers

•


•

Exhaust Gas Recirculating (EGR) System

•


Figure 367 1. 2. 3. 4. 5. 6. 7.

Exhaust manifold (typical)

Rear exhaust manifold Middle exhaust manifold M10 x 57 Torx® bolt and sleeve spacer (18) Front exhaust manifold Exhaust manifold gasket (6) M8 x 12 bolt Heat protection shield

2. Remove 18 M10 x 57 Torx® bolts and 18 sleeve spacers. Discard bolts and spacers after removal. 3. Remove exhaust manifold assembly and discard six exhaust manifold gaskets.




Figure 368 1. 2. 3. 4.

277

Exhaust manifolds

Rear exhaust manifold Middle exhaust manifold Multipiece oil (FEY) ring (4) Front exhaust manifold

Figure 369 1. 2. 3.


M8 x 50 bolt M8 x 100 bolt (2) Air intake throttle horizontal duct

4. Separate front and rear exhaust manifold sections from middle exhaust manifold. 5. Remove and discard multipiece oil (FEY) rings from front and rear exhaust manifolds.

Air Intake Throttle Duct CAUTION: To prevent engine damage, make sure gasket debris and dirt do not enter cylinder head opening. 1. Remove glow plug from air intake throttle duct. See “COLD START ASSIST” for procedure. 2. Remove temperature sensor and air pressure sensor from air intake throttle duct. See “ENGINE ELECTRICAL” for procedures.

Figure 370 1. 2. 3.


M8 x 50 bolt M8 x 100 bolt (2) Air intake throttle vertical duct

3. Remove M8 x 50 bolt and two M8 x 100 bolts. 4. Depending on application, remove either air intake throttle horizontal or vertical duct.



278

Cleaning, Inspection and Testing Air Intake Throttle Duct and Exhaust Manifolds NOTE: Do not use air tools or abrasive pads to clean aluminum parts. Air intake throttle duct and three exhaust manifold sections are castings and may be cleaned with steam or suitable non-caustic solvents. 1. Clean cylinder head, air intake throttle duct and exhaust manifold gasket sealing surfaces.

1. Use a straightedge and feeler gauge (page 282) to check seating surface flatness of three exhaust manifold sections. 2. Check for flatness across left, right and diagonally of each exhaust manifold section individually. See exhaust manifold maximum allowable warpage specification (page 282). 3. If specification is not met, replace individual exhaust manifold section. Do not resurface.

2. Clean multipiece oil (FEY) ring grooves and sealing surfaces of the exhaust manifold sections.

Manifold Warp Test for Exhaust Manifolds

Figure 371 1. 2. 3.

Exhaust manifold section warp test

Left Right Diagonally



Installation Air Intake Throttle Duct

279

2. Depending on application, install either horizontal or vertical air intake throttle duct. 3. Install M8 x 50 bolt and two M8 x 100 bolts. Tighten bolts to standard torque (page 471). 4. Install charge air cooler temperature sensor and intake manifold pressure sensor to air intake throttle duct. See “ENGINE ELECTRICAL” for procedures. 5. Install cold start fuel ignitor to air intake throttle duct. See “COLD START ASSIST” for procedure. Exhaust Manifold

Figure 372 1. 2. 3.


M8 x 50 bolt M8 x 100 bolt (2) Air intake throttle horizontal duct

CAUTION: To prevent engine damage, hand torque all fasteners of the exhaust manifolds. The exhaust manifold hardware has a special high-temperature coating which will be damaged by air tools. CAUTION: To prevent engine damage, do not reuse sleeve spacers or exhaust manifold bolts. NOTE: Do not apply anti-seize compound to threads.

Figure 374 1. 2. 3. 4.

Figure 373 1. 2. 3.


M8 x 50 bolt M8 x 100 bolt (2) Air intake throttle vertical duct

1. Apply Wacker® A-442 RTV sealant or equivalent (page 282) to joining surfaces of air intake throttle duct and cylinder head.

Exhaust manifold

Rear exhaust manifold Middle exhaust manifold Multipiece oil (FEY) ring (4) Front exhaust manifold

NOTE: Each multipiece oil (FEY) ring replacement There are two comes as four individual rings. multipiece oil rings (two sets of four rings) for each front and rear exhaust manifold section. This results in four sets of four individual rings or 16 total individual rings for a complete exhaust manifold assembly. Each set of four rings in an exhaust manifold groove must have the ring gaps indexed 180 degrees apart (6 and 12 o’clock positions).



280

1. Install four new multipiece oil (FEY) rings, two to the front exhaust manifold and two to the rear exhaust manifold, using FEY Rings Installation Tools (page 282). Refer to the tool kit installation instructions. Each multipiece oil ring (four individual rings) must be positioned with the four individual ring gaps alternating at 6 and 12 o’clock positions within each exhaust manifold ring groove.

NOTE: Ensure that raised part of exhaust manifold gasket is facing out towards exhaust manifold. 3. Position six new exhaust manifold gaskets and install exhaust manifold assembly.

2. Install the front and rear exhaust manifolds into the middle exhaust manifold.

Figure 376 sequence

Figure 375 1. 2. 3. 4. 5. 6. 7.

Exhaust manifold

Rear exhaust manifold Middle exhaust manifold M10 x 57 Torx® bolt and sleeve spacers (18) Front exhaust manifold Manifold exhaust gasket (6) M8 x 12 bolt Heat protection shield

Exhaust manifold tightening

4. Install 18 new M10 x 57 Torx® bolts and 18 new sleeve spacers. a. Tighten all bolts to 40 N·m (30 lbf·ft) using tightening sequence shown. b. Turn all bolts an additional 90° using tightening sequence shown.



281

5. Install heat protection shield to exhaust manifold. 6. Install M8 x 12 bolt. torque(page 471).

Figure 377 1. 2.

Tighten bolt to standard

Heat protection shield

Heat protection shield (at front exhaust manifold) M8 x 12 bolt



282


Exhaust Manifolds

Exhaust manifold maximum allowable warpage

0.1 mm (0.003 in)


Air Intake Throttle Duct and Exhaust Manifolds

Exhaust manifold Torx® bolts, M10 x 57

(Installation, page 279)



Description

Tool Number

Feeler gauge

Obtain locally

FEY Rings Installation Tools

ZTSE6030

Straightedge

Obtain locally


Obtain locally


FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED COMPONENTS

283

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 Pulley (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 High Mount Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 Automatic Belt Tensioner and Idler Pulleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295 Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 Coolant Control Valve (CCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299 Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301 Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303 Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303 Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303 Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304 Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304 Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305 Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305 Coolant Control Valve (CCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307 Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308 Automatic Belt Tensioner and Idler Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308 Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309 High Mount Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310 Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 Pulley (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313


284




Exploded Views

Figure 378 1. 2. 3. 4. 5. 6.

High mount fan drive system and vibration damper

Fan drive clutch assembly Tensioner bracket M8 x 30 bolt (3) M10 x 35 bolt (9) Vibration damper Damper hub (low mount fan only)

7.

Fan drive pulley (high mount fan only) 8. M16 x 85 socket-head screw (8) 9. Fan drive tensioner assembly 10. M10 x 70 countersunk screw 11. M10 x 150 bolt - 12.9 (5) 12. M10 x 65 bolt

13. Shoulder bolt 14. Pulley assembly


285

286


Figure 379

Accessory drive system (typical)

1. 2. 3.

Water pump pulley Idler pulley (2) Automatic belt tensioner

4. 5.

High-pressure pump pulley (accessory belt drive) M16 x 40 bolt

6. 7. 8.

M10 x 70 countersunk screw M12 x 55 bolt (2) M8 x 16 bolt (4)



Figure 380 1. 2.

Thermostat assembly and coolant outlet manifold (low mount fan)

M8 x 70 bolt Fan coupling bracket assembly

3. 4.

Coolant outlet manifold Thermostat assembly (2)

5. 6.

Bushing (2) M8 x 130 bolt (2)


287

288


Figure 381

Thermostat assembly and coolant outlet manifold (high mount fan)

1.

M8 x 70 bolt (3)

2.

Coolant outlet manifold (to radiator)

3.

Thermostat assembly (2)



289

Figure 382 Water pump assembly, Coolant Control Valve (CCV), water distribution housing, thermostat housing and EGR cooler return manifold 1. 2. 3. 4. 5. 6. 7. 8. 9.

Extension tube (DMR40 / DN32F) (2) Extension tube (DMR62 / 51) M8 x 30 bolt M8 x 75 bolt EGR cooler return manifold M8 x 145 bolt (4) Housing thermostat gasket M8 x 60 bolt Thermostat housing

10. 11. 12. 13. 14. 15. 16. 17.

Gasket Water distribution housing Dowel (2) Water pump assembly M8 x 40 bolt (7) M8 x 130 bolt M8 x 150 bolt (2) M8 x 150 bolt (tightens into oil module assembly) 18. Water pump gasket

19. 20. 21. 22. 23.

Engine water inlet CCV assembly M8 x 60 stud bolt (2) Lock washer (2) Housing coolant distribution gasket 24. O-ring


290


Figure 383

Front belt-driven fan cover (high mount fan)

1. 2. 3.

Front belt driven fan cover Front cover gasket Dowel pin (2)

4. 5. 6.

M12 x 75 bolt (3) Radial shaft seal M8 x 25 bolt (13)

7. 8.

M8 x 40 bolt (2) M12 x 30 bolt (2)



Figure 384 1. 2. 3.

Front gear-driven fan cover (low mount fan)

Front gear driven fan cover Front cover gasket O-ring 108 x 3

4. 5. 6.

Dowel pin (2) M12 x 75 bolt (3) Radial shaft seal

7. 8. 9.

M8 x 25 bolt (13) M8 x 40 bolt (2) M12 x 30 bolt (2)


291

292


Figure 385

Fan low mount drive (typical)

1. 2.

M8 x 25 bolt (4) Radial shaft seal

3. 4.

O-ring 108 x 3 Fan low mount drive assembly

5.

M8 x 40 bolt



Removal

293

Pulley (High Mount Fan)



Figure 386 1. 2.

Pulley assembly

Shoulder bolt Pulley assembly

1. Remove shoulder bolt and pulley assembly.

Tensioner Bracket (High Mount Fan)

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. NOTE: Refer to the following service sections for information on removal of components prior to this section. •

Engine Electrical

•


Figure 387 mount) 1. 2.

Fan drive tensioner assembly (high

Fan drive tensioner assembly M10 x 70 countersunk screw



294

1. Remove M10 x 70 countersunk screw and fan drive tensioner.

1. Disconnect air line from back of fan drive clutch assembly. 2. Remove five M10 x 150 - 12.9 bolts and M10 x 65 bolt. Remove fan drive clutch. 3. Discard six M10 bolts.

Coolant Outlet Manifold and Thermostat Assembly

Figure 388 1. 2.

Tensioner bracket

M8 x 30 bolt (3) Tensioner bracket

2. Remove three M8 x 30 bolts and tensioner bracket. High Mount Fan Drive

Figure 389 1. 2. 3.

Figure 390 fan) 1. 2. 3. 4. 5.

Coolant outlet manifold (low mount

M8 x 70 bolt M8 x 130 bolt (2) Fan coupling bracket Coolant outlet manifold Bushing (2)

Fan drive clutch assembly (typical)

Fan drive clutch assembly M10 x 150 - 12.9 bolt (5) M10 x 65 bolt EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved


Figure 392 Figure 391 fan) 1. 2.

Coolant outlet manifold (high mount

M8 x 70 bolt (3) Coolant outlet manifold

1. Remove coolant outlet manifold bolts as follows. a. If equipped with low mount fan, remove M8 x 70 bolt, two M8 x 130 bolts, bracket and two bushings.

1. 2. 3. 4.

295

Thermostat assembly

Thermostat housing Seals (part of thermostat assembly) (2) Thermostat assembly (2) Ball valves (part of thermostat assembly)

3. Remove two thermostat thermostat housing.

assemblies

from

Automatic Belt Tensioner and Idler Pulleys

b. If equipped with high mount fan, remove three M8 x 70 bolts. 2. Remove coolant outlet manifold.

Figure 393 Automatic belt tensioner and idler pulleys (typical) 1. 2. 3. 4.

Idler pulley (2) M12 x 55 bolt (2) M10 x 70 countersunk screw Automatic belt tensioner



296

1. Remove two M12 x 55 bolts and idler pulleys. CAUTION: To prevent engine damage, do not twist the belt tensioner; damage to the locating pin may occur, resulting in improper alignment of the belt tensioner. 2. Remove M10 x 70 countersunk screw and automatic belt tensioner.

2. Remove M8 x 130, M8 x 150 and seven M8 x 40 bolts. CAUTION: To prevent engine damage, do not drop water pump impeller or hit impeller with hard objects. 3. Remove water pump assembly and discard water pump gasket.

Vibration Damper Water Pump Assembly and Pulley

Figure 394 1. 2. 3. 4. 5. 6.

Water pump assembly and pulley

Water pump assembly Water pump pulley M8 x 16 bolt (4) M8 x 130 bolt M8 x 150 bolt M8 x 40 bolt (7)

1. Remove four M8 x 16 bolts and water pump pulley.

Figure 395 Vibration damper (low mount fan with damper hub) 1. 2. 3. 4.

M16 x 85 socket-head cap screw (8) Vibration damper Damper hub M10 x 35 bolt (9)

NOTE: If the oil module is removed, the M8 x 150 bolt is also removed.



297

Coolant Control Valve (CCV) Assembly

Figure 396 Vibration damper (high mount fan with fan drive pulley) 1. 2. 3. 4.

M16 x 85 socket-head cap screw (8) Vibration damper Fan drive pulley M10 x 35 bolt (9)

WARNING: To prevent personal injury or death, support the vibration damper when removing bolts. The damper can easily slide off the crankshaft. NOTE: If equipped with high mount fan, remove fan drive pulley and vibration damper together. If equipped with low mount fan, remove damper hub and vibration damper together.

Figure 397 1. 2. 3. 4. 5. 6. 7.

CCV assembly

Low temperature hose assembly Hose clamp (spring type) Coolant Mixer Valve (CMV) Coolant Flow Valve (CFV) Lock washer (2) M8 x 60 stud bolt (2) CCV assembly

1. Release hose clamp (spring type) and remove low temperature hose assembly from CCV assembly. 2. Remove two M8 x 60 stud bolts, two lock washers, CCV assembly and O-ring. Discard O-ring.

1. Remove eight M16 x 85 socket-head cap screws. 2. Remove vibration damper with damper hub or fan drive pulley as an assembly. 3. For vibration damper replacement only, remove damper hub or fan drive pulley by removing nine M10 x 35 bolts.



298

Thermostat Housing

Figure 399

Figure 398 1. 2. 3. 4.

EGR cooler return manifold

EGR cooler return manifold M8 x 145 bolt (4) M8 x 30 bolt Extension tube (DMR62 / 51)

1. 2. 3.

Thermostat housing

Thermostat housing M8 x 75 bolt M8 x 60 bolt

4. Remove M8 x 75 bolt and M8 x 60 bolt. 5. Remove thermostat housing and discard gasket.

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface. 1. Remove extension tube (DMR62 / 51) from manifold. Inspect extension tube for damage, replace as needed. 2. Remove four M8 x 145 bolts and one M8 x 30 bolt. 3. Remove EGR cooler return manifold and discard gasket.

Figure 400 1. 2.

Thermostat housing

Extension tube (DMR40 / DN32F) (2) Thermostat housing

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface with pliers or other tools that can mar the surface.


FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED COMPONENTS 6. Remove two extension tubes (DMR40 / DN32F) from thermostat housing using a wood-handled tool. Gently pry the extension tubes out until removed. Inspect extension tubes for damage, replace as needed.

Water Distribution Housing

299

2. Remove water distribution housing and discard gasket. 3. Remove two M10 x 30 bolts and separate engine water inlet from water distribution housing. Remove and discard gasket. 4. Remove coolant heater from engine water inlet as needed.

Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal


Water distribution housing

Water distribution housing M10 x 110 bolt with low mount fan drive or M10 x 150 - 12.9 bolt with high mount fan drive (5) M8 x 150 bolt (2) Engine water inlet (94°) Coolant heater M10 x 30 bolt (2) M10 x 65 bolt (only with high mount fan)

3. 4. 5. 6. 7.

1. Remove two M8 x 150 bolts. •

If equipped with low mount fan drive, five M10 x 110 bolts.

•

If equipped with high mount fan drive, five M10 x 150 - 12.9 bolts and one M10 x 65 bolt. (These bolts are removed with high mount fan drive clutch assembly removal.)

1. 2.

Radial shaft seal removal

Radial shaft seal Slide hammer

WARNING: To prevent personal injury or death, wear safety glasses with side shields when doing the following procedure. 1. With an awl and hammer, punch two holes 180° apart in front oil seal. 2. Thread a slide hammer (page 313) with correct size screw in one of the two holes. 3. Slide hammer until one side of seal begins to pull out of cover. Move slide hammer to other hole and repeat until front oil seal is removed.


300


Front Belt- or Gear-Driven Fan Cover

Radial Shaft Seal (Fan Low Mount Drive) WARNING: To prevent personal injury or death, wear safety glasses with side shields. 1. With an awl and hammer, punch two holes 180° apart in radial shaft seal.

Figure 403 Front belt- or gear-driven fan cover bolts (high mount cover shown) 1. 2. 3. 4.

M8 x 25 bolt (13) M12 x 75 bolt (3) M8 x 40 bolt (2) M12 x 30 bolt (2)

WARNING: To prevent personal injury or death, use a suitable lifting device and get help when removing, lowering and installing the front cover.

Figure 404

Radial shaft seal removal

2. Thread a slide hammer (page 313) with correct size screw in one of the two holes. 3. Slide hammer until one side of seal begins to pull out of fan drive. Move slide hammer to other hole and repeat until radial shaft seal is removed. Discard radial shaft seal.

1. Remove two M8 x 40 bolts, two M12 x 30 bolts, three M12 x 75 bolts and 13 M8 x 25 bolts. 2. Remove front belt- or gear-driven fan cover and front cover gasket from crankcase dowels. Discard front cover gasket.



301

Fan Low Mount Drive Assembly

Figure 406 Figure 405

O-ring 108 x 3

1. 2. 3.

Fan low mount drive assembly

M8 x 25 bolt (4) Fan low mount drive assembly M8 x 40 bolt

1. Remove and discard O-ring 108 x 3. 2. Remove four M8 x 25 bolts, one M8 x 40 bolt and fan low mount drive assembly.


302


Cleaning, Inspection and Testing WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 1. Clean water distribution housing, water pump, coolant outlet manifold, thermostat housing and front belt- or gear-driven fan cover with a suitable non-caustic solvent. 2. Blow parts dry using filtered compressed air. 3. Clean coolant and oil seal mating surfaces on the crankcase, cylinder head, water distribution housing, water pump assembly, coolant outlet manifold, thermostat housing and front belt- or gear-driven fan cover. 4. Inspect water distribution housing, coolant outlet manifold, vibration damper and front belt- or gear-driven fan cover for damage, contamination or excessive wear. Replace parts if required.

5. Inspect belt automatic tensioners and pulleys to make sure tensioner arms and pulleys are properly in line with the fan drive belt and accessory drive belt and not coming apart. Make sure tensioner arms are not binding and pulley bearings are not loose. Replace belt tensioners if required. 6. Inspect idler pulleys to make sure pulleys are properly in line with the fan drive belt and accessory drive belt and not coming apart. Replace idler pulleys if required. 7. Inspect thermostat assemblies. If thermostat assembly elements are stuck open, damaged, cracked or not opening properly, replace thermostat assemblies. 8. Inspect water pump assembly. Wiggle water pump assembly hub and shaft. If water pump assembly bearing has excess play, replace water pump assembly. Inspect water distribution housing and water pump assembly for coolant leaks. Replace if leaking.



Installation Fan Low Mount Drive Assembly

303

2. Lubricate new O-ring 108 x 3 with clean engine oil and install on fan low mount drive assembly.

Radial Shaft Seal (Fan Low Mount Drive) 1. Lubricate radial shaft seal with clean engine oil.

Figure 407 1. 2. 3.

Fan low mount drive assembly

M8 x 25 bolt (4) Fan low mount drive assembly M8 x 40 bolt

1. Install fan low mount drive, M8 x 40 bolt and four M8 x 25 bolts. Tighten bolts to standard torque (page 471).

Figure 409 1. 2.

Radial shaft seal installation

Fan Seal Installer Fan low mount drive assembly

2. Using Fan Seal Installer (page 313), install new radial shaft seal until fully seated.

Figure 408

O-ring 108 x 3


304


Front Belt- or Gear-Driven Fan Cover

Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal

Figure 411 Figure 410 Front belt- or gear-driven fan cover bolts (typical) 1. 2. 3. 4.

M8 x 25 bolt (13) M12 x 75 bolt (3) M8 x 40 bolt (2) M12 x 30 bolt (2)

1. 2.

Radial shaft seal installation (typical)

Front belt- or gear-driven fan cover Front Crankshaft Seal Installer

CAUTION: To avoid damage to the radial shaft seal, do not touch inner seal lip, allow oil or grease on any part of the seal during installation. 1. Using Front Crankshaft Seal Installer (page 313), install a new radial shaft seal into the front cover.

WARNING: To prevent personal injury or death, use a suitable lifting device and get help when removing, lowering and installing the front cover.

a. Install inner hub of tool to crankshaft flange. Use two bolts provided to secure tool.

1. Position a new front cover gasket on crankcase dowels.

c.

b. Install radial shaft seal to inner hub of tool. Install pressing hub and nut and tighten to install radial shaft seal. When tool bottoms out, seal is fully installed.

2. Install front cover on crankcase dowels. 3. Install two M8 x 40 bolts, two M12 x 30 bolts, three M12 x 75 bolts and 13 M8 x 25 bolts in locations shown. Tighten M8 bolts to standard torque (page 471). Tighten M12 bolts to special torque (page 312).


FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED COMPONENTS Water Distribution Housing

305

4. Install water distribution housing and secure as follows: •

If equipped with low mount fan drive, use five M10 x 110 bolts.

•

If equipped with high mount fan drive, use five M10 x 150 - 12.9 bolts and one M10 x 65 bolt. (These bolts are installed with high mount fan drive clutch assembly installation.)

Tighten low mount fan drive bolts to special torque (page 312).

Thermostat Housing

Figure 412 1. 2. 3. 4. 5. 6. 7.

Water distribution housing

Water distribution housing M10 x 110 bolt with low mount fan drive or M10 x 150 bolt - 12.9 with high mount fan drive (5) M8 x 150 bolt (2) Engine water inlet (94°) Coolant heater M10 x 30 bolt (2) M10 x 65 bolt (only with high mount fan)

1. Install coolant heater into engine water inlet as needed. Tighten to special torque (page 312). 2. Install new gasket and install engine water inlet and two M10 x 30 bolts to water distribution housing. Tighten bolts to special torque (page 312). 3. Lubricate a new water distribution housing gasket with clean coolant and install into water distribution housing.

Figure 413 1. 2.

Thermostat housing

Extension tube (DMR40 / DN32F) (2) Thermostat housing

1. Lubricate sealing surfaces of two extension tubes (DMR40 / DN32F) with P-80® rubber lubricant or equivalent (page 313) and install into thermostat housing using Extension Tube Installer Small (page 313).



306

4. Install new thermostat housing gasket and EGR cooler return manifold. 5. Install four M8 x 145 bolts and one M8 x 30 bolt. Tighten bolts to special torque (page 312). 6. Tighten M8 x 75 and M8 x 60 thermostat housing bolts to special torque (page 312). 7. Lubricate sealing surfaces of extension tube (DMR62 / 51) with P-80® rubber lubricant or equivalent (page 313) and install into EGR cooler return manifold using Extension Tube Installer Large (page 313).

Figure 414 1. 2. 3.

Thermostat housing

Coolant Control Valve (CCV) Assembly

Thermostat housing M8 x 75 bolt M8 x 60 bolt

2. Install new gasket and thermostat housing. 3. Install M8 x 75 bolt and M8 x 60 bolt. Do not tighten bolts until EGR cooler return manifold is installed.

Figure 416 1. 2. 3. 4. 5. 6. 7.

Figure 415 1. 2. 3. 4.

CCV assembly

Low temperature EGR hose assembly Hose clamp (spring type) Coolant Mixer Valve (CMV) Coolant Flow Valve (CFV) Lock washer (2) M8 x 60 stud bolt (2) CCV assembly

EGR cooler return manifold

EGR cooler return manifold M8 x 145 bolt (4) M8 x 30 bolt Extension tube (DMR62 / 51)

1. Install a new O-ring on the CCV assembly. 2. Install CCV assembly, two lock washers and two M8 x 60 stud bolts. Tighten stud bolts to special torque (page 312). 3. Install low temperature hose assembly and secure with hose clamp (spring type).



307

Vibration Damper

Figure 417 Vibration damper (low mount fan with damper hub) 1. 2. 3. 4.

M16 x 85 socket-head cap screw (8) Vibration damper Damper hub M10 x 35 bolt (9)

Figure 418 Vibration damper (high mount fan with fan drive pulley) 1. 2. 3. 4.

M16 x 85 socket-head cap screw (8) Vibration damper Fan drive pulley M10 x 35 bolt (9)

NOTE: Install damper hub or fan drive pulley and vibration damper together as an assembly. 1. If previously disassembled, assemble damper hub or fan drive pulley to vibration damper with nine M10 x 35 bolts. Tighten bolts to special torque (page 312). 2. Install vibration damper assembly. 3. Install eight M16 x 85 socket-head cap screws. Using a crisscross pattern, tighten screws as follows. a. Tighten socket-head cap screws to 150 N·m (111 lbf·ft). b. Angle-tighten socket-head cap screws an additional 90°.



308

Water Pump Assembly and Pulley

Figure 419 1. 2. 3. 4. 5. 6.

Automatic Belt Tensioner and Idler Pulley

Water pump assembly and pulley

Water pump assembly Water pump pulley M8 x 16 bolt (4) M8 x 130 bolt M8 x 150 bolt M8 x 40 bolt (7)

NOTE: If the oil module is removed, the M8 x 150 bolt is installed along with oil module.

Figure 420 Automatic belt tensioner and idler pulley (typical) 1. 2. 3. 4.

Idler pulley (2) M12 x 55 bolt (2) M10 x 70 countersunk screw Automatic belt tensioner

1. Lubricate a new water pump gasket with clean coolant and install onto water pump.

CAUTION: To prevent engine damage, do not twist the belt tensioner; damage to the locating pin may occur, resulting in improper alignment of the belt tensioner.

2. Install water pump and secure with one M8 x 130, one M8 x 150 and seven M8 x 40 bolts in location shown. Tighten M8 bolts to special torque (page 312).

1. Install automatic belt tensioner and M10 x 70 countersunk screw. Make sure locating pin is placed into locating hole. Tighten countersunk screw to special torque (page 312).

3. Install water pump pulley and four M8 x 16 bolts. Tighten bolts to special torque (page 312).

2. Install two idler pulleys and two M12 x 55 bolts. Tighten bolts to special torque (page 312).



309

Coolant Outlet Manifold and Thermostat Assembly

Figure 421 1. 2. 3. 4.

Thermostat assembly

Thermostat housing Seals (part of thermostat assembly) (2) Thermostat assembly (2) Ball valves (part of thermostat assembly)

1. Install two thermostat assemblies into thermostat housing with ball valves at 12 o’clock position.

Figure 423 fan) 1. 2.

Coolant outlet manifold (high mount

M8 x 70 bolt (3) Coolant outlet manifold

2. Install coolant outlet manifold. 3. If equipped with low mount fan, install bracket and two bushings. 4. Install coolant outlet manifold bolts as follows. a. If equipped with low mount fan, install one M8 x 70 bolt and two M8 x 130 bolts. Tighten bolts to special torque (page 312). b. If equipped with high mount fan, install three M8 x 70 bolts. Tighten bolts to special torque (page 312).

Figure 422 fan) 1. 2. 3. 4. 5.

Coolant outlet manifold (low mount

M8 x 70 bolt M8 x 130 bolt (2) Fan coupling bracket Coolant outlet manifold Bushing (2) EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved


310

High Mount Fan Drive

Figure 424 1. 2. 3.

2. Install fan drive clutch assembly and five new M10 x 150 - 12.9 and one new M10 x 65 bolt with engine oil lightly applied to threads.

Fan drive clutch assembly (typical)

Fan drive clutch assembly M10 x 150 - 12.9 bolt (5) M10 x 65 bolt

CAUTION: To prevent engine damage, clean and blow dry crankcase bolt holes with filtered compressed air. Debris or fluids in bolt holes may cause binding and incorrect bolt torque. WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 1. Using filtered compressed air, clean thread holes of fan drive clutch assembly.

Figure 425 sequence

High mount fan drive bolt tightening

3. Tighten M10 bolts using sequence indicated above as follows. a. Tighten six M10 bolts to 37 N·m (27 lbf·ft). b. Re-tighten six bolts to 37 N·m (27 lbf·ft). c.

Angle-tighten five M10 x 150 - 12.9 bolts an additional 90° in sequence.

d. Tighten M10 x 65 bolt to 62 N·m (46 lbf·ft). 4. Connect air line to back of fan drive clutch assembly.


FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED COMPONENTS Tensioner Bracket (High Mount Fan)

311

2. Install fan drive tensioner and M10 x 70 countersunk screw. Make sure locating pin is placed into locating hole. Tighten countersunk screw to special torque (page 312).

Pulley (High Mount Fan)

Figure 426 1. 2.

Tensioner bracket

M8 x 30 bolt (3) Tensioner bracket

1. Install tensioner bracket and three M8 x 30 bolts. Tighten bolts to standard torque (page 471).

Figure 428 1. 2.

Pulley assembly

Shoulder bolt Pulley assembly

1. Install pulley assembly and shoulder bolt. Tighten shoulder bolt to special torque (page 312).

Figure 427 mount) 1. 2.

Fan drive tensioner assembly (high

Fan drive tensioner assembly M10 x 70 countersunk screw



312



Automatic belt tensioner countersunk screw, M10 x 70

47 N·m (35 lbf·ft)

CCV assembly stud bolts (with lock washers), M8 x 60

35 N·m (26 lbf·ft)

Coolant heater

41 N·m (30 lbf·ft)

Coolant outlet manifold bolts, M8

35 N·m (26 lbf·ft)

Damper hub and fan drive pulley bolts to vibration damper, M10 x 35

45 N·m (33 lbf·ft)

EGR cooler return manifold bolts, M8

35 N·m (26 lbf·ft)

Engine water inlet bolts, M10 x 30

29 N·m (21 lbf·ft)

Front belt- or gear-driven fan cover bolts, •

M12 x 75

115 N·m (85 lbf·ft)

•

M12 x 30

115 N·m (85 lbf·ft)

High mount fan drive clutch assembly bolts, M10


High mount fan drive tensioner countersunk screw, M10 x 70

47 N·m (35 lbf·ft)

High mount fan pulley assembly shoulder bolt

62 N·m (46 lbf·ft)

Idler pulley bolt, M12 x 55

60 N·m (44 lbf·ft)

Low mount fan drive bolt, M10 x 110

37 N·m (27 lbf·ft)

Thermostat housing bolts, M8

35 N·m (26 lbf·ft)

Vibration damper socket-head cap screws, M16 x 85


Water distribution housing bolts, M8

35 N·m (26 lbf·ft)

Water pump assembly bolts, M8

35 N·m (26 lbf·ft)

Water pump pulley bolts, M8 x 16

17 N·m (13 lbf·ft)



313



Description

Tool Number


ZTSE6046


ZTSE6047

Fan Seal Installer

ZTSE6066

Front Crankshaft Seal Installer

ZTSE4873


Obtain locally

Slide hammer

Obtain locally


314



MAXXFORCE® ENGINE BRAKE BY JACOBS

315

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321 Master Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322 Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 Master Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327 Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328 Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328 Engine Brake Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330


316




Exploded Views

Figure 429 1. 2. 3.

MaxxForce® engine brake assembly installation

M10 x 90 bolt (6) M12 x 100 (socket-head) screw (6) Engine brake housing assembly (2)

4. 5. 6.

M12 x 60 (socket-head) screw (6) Intake and exhaust rocker arm assembly (6) Valve bridge (intake) (6)

7.

Valve bridge (exhaust) (6)


317


318

Figure 430 1. 2. 3. 4. 5. 6. 7.

MaxxForce® engine brake housing assembly

Master piston roller assembly Master piston roller spring Master piston spring guide Solenoid assembly M6 x 10 socket-head cap screw Solenoid cover Solenoid screen

8. 9. 10. 11. 12. 13. 14.

Control valve retaining ring Control valve cover Outer spring Inner spring Control valve assembly M10 (jam) nut Slave piston adjusting screw

15. 16. 17. 18. 19. 20.

Slave piston Slave piston spring Slave piston washer Slave piston retaining ring M6 x 30 master piston guide bolt Master piston guide sleeve



Figure 431 1. 2.

Engine injector wiring harness with engine brake solenoid leads

Solenoid assembly (2) Solenoid connector nut (part of harness connector) (4)

3. 4.

Engine brake assembly (2) Engine brake solenoid harness connector lead (2)

5. 6.

Engine injector harness assembly Tie strap (3)


319


320

Removal Engine Brake Housing Assembly

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminated materials according to applicable regulations. Figure 432 WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure that the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. WARNING: To prevent personal injury or death, disconnect the main battery negative terminal before disconnecting or connecting electrical components.

1. 2. 3. 4.

Engine brake assembly

M12 x 100 (socket-head) screw (6) M10 x 90 bolt (6) Solenoid connector nut (4) Tie strap (3)

1. Remove upper valve cover. See Upper Valve Cover and Base in the “CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN” section (Upper Valve Cover and Base, page 341). 2. Disconnect brake wiring harness connector leads from solenoid by disengaging two connector nuts on each front and rear engine brake housing assemblies. The connector nuts are retained by the harness connectors. 3. Cut tie straps securing solenoid harness connector leads on front and rear brake housings. Position leads out of the way. 4. Mark housings to indicate front and rear to insure they are reinstalled later in the correct locations. 5. Remove three M12 x 100 socket-head screws and three M10 x 90 bolts and remove front engine brake housing assembly from cylinder head. 6. Repeat step 5 to remove rear brake housing assembly.

Disassembly NOTE: When disassembling the engine brake housing, keep all component parts together in sets and if reused, reinstall each set back in its original location. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

MAXXFORCE® ENGINE BRAKE BY JACOBS Solenoid

Figure 433 1. 2. 3. 4.

321

Control Valve

Solenoid

Solenoid assembly M6 x 10 socket-head cap screw Solenoid cover Solenoid screen

Figure 434 1. If not already done, loosen connector nuts and disconnect harness connector leads from solenoid. 2. Remove M6 x 10 socket-head cap screw. NOTE: Cover slides over solenoid and locks onto terminal ends. Cover is removed with solenoid as an assembly.

1. 2. 3. 4. 5.

Control valve

Control valve retaining ring Control valve cover Outer spring Inner spring Control valve assembly

3. Remove solenoid and cover from brake housing.


4. Remove upper and lower seal rings from solenoid stem. Discard seal rings.

NOTE: Use same procedure to remove all control valves from engine.

5. Remove and discard solenoid screen.

1. Push down on control valve cover and hold to remove spring pressure from control valve retaining ring. Using suitable snap-ring pliers, remove control valve retaining ring from housing control valve bore. Slowly release control valve cover to relieve spring pressure. 2. Remove control valve cover from valve bore. 3. Using a pick, carefully remove inner and outer springs from bore.



322

4. Using a magnet or needle-nose pliers, remove control valve from housing bore.

Slave Piston

Master Piston

Figure 435 1. 2. 3. 4. 5.

Master piston

Master piston spring guide Master piston roller spring Master piston roller assembly M6 x 30 master piston guide bolt Master piston guide sleeve

The master piston group currently is not a serviceable part. If a fault condition is traced to a malfunctioning master piston, replace brake housing assembly.

Figure 436 1. 2. 3. 4. 5. 6.

Slave piston

M10 (jam) nut Slave piston adjusting screw Slave piston Slave piston spring Slave piston washer Slave piston retaining ring

WARNING: To prevent personal injury or death, use Jacobs® Slave Piston Removal Tool to remove or install slave piston. Slave piston springs are under heavy compression. WARNING: To prevent personal injury or death, wear safety glasses with side shields. 1. Remove M10 jam nut and back out slave piston adjusting screw until slave piston is fully retracted. Use same procedure to remove all slave pistons from the engine.



Figure 437 1. 2.

Slave Piston Removal Tool

Clamp screw collar Slave Piston Removal Tool

Figure 438 1. 2.

323

Slave piston retaining ring

Slave piston retaining ring Slave Piston Removal Tool

2. Place Jacobs® Slave Piston Removal Tool in position with hole in tool clamp bracket over slave piston adjusting screw and clamp screw collar over slave piston stem.


3. Slowly tighten clamp screw until collar contacts slave piston washer. Continue tightening clamp screw to compress slave piston spring and relieve spring pressure against slave piston retaining ring.

5. Slowly loosen tool clamp screw to release slave piston spring pressure and remove tool.

4. Using snap-ring pliers, remove slave piston retaining ring from piston bore.

6. Grasp piston stem and remove slave piston, spring and washer. 7. Remove slave piston adjusting screw.


324


Cleaning and Inspection WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 1. Clean brake housings, control valve assemblies, master piston rollers, slave pistons and springs with a suitable non-caustic solvent. 2. Blow parts dry using filtered compressed air. 3. Inspect brake housings for cracks. Replace as required. 4. Check for missing or loose pipe plugs at sides and ends of brake housings. If pipe plugs are missing or loose, replace brake housing assembly. 5. Inspect master piston rollers and associated camshaft lobes for excessive wear, spalling and galling. Replace complete brake housing assembly if any master piston roller is determined unacceptable to reuse. If camshaft lobes for engine brake have excessive wear, spalling or galling, replace camshaft. See “CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN” section of this manual for camshaft replacement procedures. 6. Inspect slave pistons, springs and control valve assembly for worn or damaged parts. Replace parts that are broken or deformed. 7. Inspect slave piston bores in brake housing. Insert slave pistons in respective bores and check for free movement without binding. If there is binding, replace brake housing assembly. 8. Inspect control valve assembly bores in brake housing. Insert control valve assemblies in respective bores and check for free movement without binding. If there is binding, replace brake housing assembly.

Figure 439 1. 2. 3.

Solenoid assembly check

Solenoid screen (removed for check) Pin Button of armature

9. Hold solenoid assembly upside down in hand so you can look into the end where the solenoid screen was removed. Move button of armature with finger while looking into the open end to verify pin moves freely within the solenoid assembly. If pin does not move freely, replace solenoid. 10. Using an ohmmeter, check solenoid assembly resistance per the following steps: •

Check resistance across the two terminals. If resistance is out of specification (page 330), replace solenoid assembly.

•

Check resistance from each terminal to the solenoid can. This should be an “open circuit.” If a resistance is measured, replace solenoid assembly.



Assembly Slave Piston

325

NOTE: Retaining ring with proper orientation must be placed on stem before using Jacobs® Slave Piston Removal Tool to compress spring in housing bore. WARNING: To prevent personal injury or death, use Jacobs® Slave Piston Removal Tool to remove or install slave piston. Slave piston springs are under heavy compression. WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 440 1. 2. 3. 4. 5. 6.

Slave piston

M10 (jam) nut Slave piston adjusting screw Slave piston Slave piston spring Slave piston washer Slave piston retaining ring

1. Check that housing slave piston bore is clean, free of any residue and debris. 2. Lubricate slave piston, spring and washer with clean engine oil. 3. Assemble slave piston spring, washer and retaining ring on slave piston stem. 4. Insert slave piston, spring and washer assembly into housing bore.

Figure 441 1. 2.


Clamp screw collar Slave Piston Removal Tool

5. Place slave piston retaining ring, oriented with sharp side up (away from washer), in position over slave piston stem. Install Jacobs® Slave Piston Removal Tool with clamp screw collar on slave piston stem. 6. Slowly tighten clamp screw until screw collar contacts slave piston washer. Continue tightening clamp screw to compress piston spring until washer is approximately 1/32 inch below retaining ring groove.



326

Master Piston



Slave piston retaining ring Slave Piston Removal Tool

7. Using snap-ring pliers, install slave piston retaining ring in bore ring groove. Ensure retaining ring is oriented with sharp side up (away from washer). Rotate retaining ring to ensure that it is properly seated in groove.

1. 2. 3. 4. 5.

Master piston

Master piston spring guide Master piston roller spring Master piston roller assembly M6 x 30 master piston guide bolt Master piston guide sleeve

The master piston group currently is not a serviceable part. If a fault condition is traced to a malfunctioning master piston, replace brake housing assembly.

8. Slowly loosen tool clamp screw to release piston spring pressure and remove tool. 9. Install slave piston adjusting screw and jam nut. Do not tighten jam nut.


MAXXFORCE® ENGINE BRAKE BY JACOBS Control Valve

327

spring on control valve and outer spring on step of control valve bore. 5. Install control valve cover over springs. WARNING: To prevent personal injury or death, wear safety glasses with side shields. 6. Using snap-ring pliers, install control valve retaining ring in housing bore to contain control valve assembly. Ensure retaining ring is installed with sharp side up (away from control valve cover). Rotate retaining ring to insure that it is properly seated in groove.

Solenoid

Figure 444 1. 2. 3. 4. 5.

Control valve

Control valve retaining ring Control valve cover Outer spring Inner spring Control valve assembly

1. Check that housing control valve bore is clean, free of any residue and debris. 2. Lubricate control valve assembly and springs with clean engine oil. 3. With hex stud end up, insert control valve assembly into housing bore. Ensure control valve assembly moves smoothly and freely down bore. 4. Insert inner and outer springs into bore. Make sure that springs are properly seated with inner

Figure 445 1. 2. 3.

Solenoid seal rings

Upper seal ring Lower seal ring Solenoid screen

1. Install new upper and lower seal rings in ring grooves on solenoid stem. Lubricate seal rings with clean engine oil. 2. Clip solenoid screen on bottom of solenoid stem.



328

Installation Engine Brake Housing Assembly

Figure 446 1. 2. 3. 4.

Solenoid

Solenoid assembly M6 x 10 socket-head cap screw Solenoid cover Solenoid screen

3. Place solenoid in position on brake housing. Using hand pressure, press solenoid into bore until it snaps into place. 4. If removed, install solenoid cover on solenoid. 5. Install M6 x 10 socket-head cap screw. Tighten screw to special torque (page 330).

Figure 447 1. 2. 3. 4.

Engine brake assembly

M12 x 100 (socket-head) screw (6) M10 x 90 bolt (6) Solenoid connector nut (4) Tie strap (3)

1. Carefully place previously marked front engine brake housing assembly in front position over camshaft and valve train. 2. Install three M12 x 100 socket-head screws and three M10 x 90 bolts. Tighten bolts to special torque (page 330). 3. Repeat steps 1 and 2 to install previously marked rear engine brake housing assembly in rear position over camshaft and valve train.


MAXXFORCE® ENGINE BRAKE BY JACOBS CAUTION: To prevent engine damage, do not over torque nuts on wiring harness connector leads. Too much torque will damage solenoid terminals.

329

Engine Brake Lash Adjustment

4. Connect brake wiring harness connector leads to solenoid on front and rear engine brake housing assemblies. Make sure harness terminal connectors are in straight alignment with harness. Hold terminal connectors stationary to avoid twisting and tighten connector nuts to special torque (page 330). 5. Install two tie straps to secure solenoid harness connector lead on front brake housing and one tie strap to secure harness connector lead on rear brake housing. 6. Adjust engine brake lash. See (Engine Brake Lash Adjustment, page 329) for procedure. 7. Install upper valve cover. See Upper Valve Cover and Base in the “CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN” section (Upper Valve Cover and Base, page 359) for procedure.

Figure 448 1. 2. 3. 4.

Engine brake lash adjustment

Slave piston adjusting screw M10 (jam) nut Actuator pin (in exhaust valve bridge) Slave piston

See Valve Lash Adjustment (Valve Lash Adjustment, page 337) for procedure covering both valve lash and engine brake lash adjustments on engines so equipped.



330 Specifications Table 26

Engine Brake

Solenoid resistance: Cold — 25 ° C (77 ° F) Hot — 121 ° C (250 ° F)

8.7–10 ohms 12–15.5 ohms


Engine Brake

Brake housing M10 x 90 bolt

75 N·m (55 lbf·ft)

Brake housing M12 x 100 (socket-head) screw

105 N·m (77 lbf-ft)

Brake housing solenoid harness connector nut

3.5 N·m (31 lbf·in)

Slave piston adjusting screw M10 (jam) nut Solenoid M6 x 10 socket-head cap screw

25 N·m (18 lbf·ft) 12.5 N·m (110 lbf·in)


Engine Brake

Description

Tool Number

Jacobs® Slave Piston Removal Tool


ZTSE6068

CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

331

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333 Periodic Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337 Valve Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337 Valve Overlap Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338 Valve Lash Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341 Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341 Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347 Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349 Cylinder Head and Crankcase Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349 Camshaft Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349 Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 Valves Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352 Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356 Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358 Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362


332




Exploded Views

Figure 449 1. 2.

Valve cover and base

Screw with damper (18) Upper valve (cover) gasket

3. 4.

M8 x 30 bolt (17) Upper valve cover

5. 6.

Valve cover base Valve cover (base) gasket


333


334

Figure 450 1.

Non-brake rocker arm assembly and valve bridges

Intake and exhaust rocker arm assembly (6)

2. 3.

M12 x 60 (socket-head) screw (12) Rocker bearing block (6)

4.

Valve bridge (intake and exhaust) (12)

NOTE: Rocker arm assemblies and valve bridges shown and covered in this section represent the standard non-brake engine configuration. For engines with optional engine brake, refer to MaxxForce® Engine Brake by Jacobs section for procedures.



Figure 451 1. 2. 3. 4.

335

Camshaft and cylinder head idler gear

M8 x 30 bolt (3) Camshaft timing disc (pulse wheel) Camshaft gear Timing (M6 x 20 dowel) pin

5. 6. 7. 8. 9.

M8 x 35 bolt (14) (Camshaft) bearing cap (7) 4H x 8 x 10 dowel pin (14) Camshaft Bearing shell (14)

10. Cylinder head idler gear 11. Small gear shaft 12. M8 x 30 socket-head cap screw (3) 13. DMR 63.10 cup plug



336

Figure 452 1. 2.

Cylinder head

Front lifting eye M18 x 2 x 246 Torx® bolt (26)

3. 4.

Cylinder head Cylinder head gasket

5. 6.

Dowel pin (2) M12 x 25 bolt (2)



Periodic Service

337

Valve Lash Adjustment NOTE: Valve lash must be set with engine cold and cylinder head assembled to crankcase.


1. Remove the upper valve cover and base. See (Upper Valve Cover and Base, page 341).

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, remove the ground cable from the negative terminal of the main battery before disconnecting or connecting electrical components. Always connect the ground cable last.

Figure 453 1. 2. 3.

Camshaft gear timing mark

Valve cover surface Camshaft gear Timing mark

2. Rotate crankshaft in direction of engine rotation until the camshaft timing gear mark aligns with the valve cover surface on the intake side of the engine.




338

5. Recheck that the timing mark on camshaft gear is aligned with the valve cover gasket surface (on intake side of cylinder head). If flywheel and camshaft gear marks are in agreement, the engine is at TDC for cylinder 1. Skip step 6 and proceed to Valve Overlap Procedure below. CAUTION: To prevent engine damage, a new large idler gear must be installed, if the large idler gear has slipped. 6. If flywheel and camshaft gear marks are not in agreement, the large idler gear has slipped. See (page 405) for procedure to install a new large idler gear. Figure 454 (typical)

Flywheel housing timing index

Valve Overlap Procedure

3. Remove timing hole cover from lower side of flywheel housing.

NOTE: Valve lash adjustments are done in firing order sequence (1, 5, 3, 6, 2, 4), using the valve overlap method. Valve overlap happens on the companion cylinder near the end of the exhaust stroke and the beginning of the intake stroke, when both valves are open for a short period of time.

4. Use a pry bar to rotate crankshaft in direction needed to align the flywheel timing mark with flywheel housing timing index.

1. Starting with cylinder 1 at TDC compression, set valve lash for cylinder 1, according to Valve Lash Adjustment Procedure below.

1. 2.

Flywheel housing timing index Flywheel timing mark

2. After valves for cylinder 1 have been adjusted, rotate crankshaft slowly and watch valves for cylinder 2; watch the exhaust valve as it closes, and watch for intake valve to start opening. When cylinder 2 intake and exhaust valves are open equally, adjust valves on cylinder 5 according to the Valve Lash Adjustment Procedure below. 3. Repeat Valve Overlap Procedure, in order for remaining cylinders 3,6,2, and 4. See Table 29 (page 340).

Figure 455 1. 2. 3.

Camshaft gear timing mark

Valve cover surface Camshaft gear Timing mark (aligned with valve cover surface)


CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN Valve Lash Adjustment Procedure

c.

339

Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to special torque (page 361).

d. Go to step 6 to complete adjustments.

Figure 456 1. 2. 3. 4. 5.

Valve lash adjustment (typical)

Exhaust rocker arm Intake rocker arm Adjusting screw M10 nut Valve bridge (intake/exhaust)

Figure 457 1. 2. 3. 4.

Valve lash adjustment (typical)

Slave piston adjusting screw M10 (jam) nut Actuator pin (in exhaust valve bridge) Slave piston

1. Loosen intake valve lash adjustment M10 nut. 2. Insert a 0.5 mm (0.020 in) feeler gauge (page 362) between intake valve bridge and adjusting screw and tighten adjusting screw until a slight drag on feeler gauge is felt. 3. Hold adjusting screw in position and tighten intake valve lash adjustment M10 x 1 nut to special torque (page 361). NOTE: If equipped with MaxxForce® engine brake, go to step 5 to adjust exhaust valve lash and engine brake lash. If no engine brake, continue with on with step 4. 4. For engine without brake, adjust exhaust valve lash as follows:

5. For engine with MaxxForce® engine brake, adjust exhaust valve lash and engine brake lash as follows: a. Loosen M10 (jam) nut and back out engine brake slave piston adjusting screw so that it no longer makes contact with valve bridge. b. Loosen exhaust valve lash adjustment M10 nut. c.

Insert a 0.8 mm (0.031 in) feeler gauge (page 362) between exhaust valve bridge and adjusting screw and tighten adjusting screw until a slight drag on feeler gauge is felt.

a. Loosen exhaust valve lash adjustment M10 nut.

d. Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to special torque (page 361).

b. Insert a 0.8 mm (0.031 in) feeler gauge (page 362) between exhaust valve bridge and adjusting screw and tighten adjusting screw until a slight drag on feeler gauge is felt.

e. Insert a 0.8 mm (0.031 in) feeler gauge (Jacobs® 96–020949 or equivalent) (page 362) between engine brake slave piston and bridge actuator pin.


340

f.


Turn adjusting screw in until slave piston contacts feeler gauge and a slight drag on feeler gauge is felt.

g. Using a 5 mm Allen wrench, hold adjusting screw to prevent it from turning and tighten jam nut to special torque (page 361). 6. Turn crankshaft in direction of engine rotation to position next cylinder in firing order at TDC compression (one at a time) and adjust lash for the respective cylinder. For each cylinder positioned at TDC compression, the companion cylinder will be in valve overlap as shown in following table.

Table 29 Cylinder at TDC compression

Companion cylinder in valve overlap

1

6

5

2

3

4

6

1

2

5

4

3



Removal NOTE: Refer to the following service sections for information on removal of components prior to this section. •

Engine Electrical

•

Turbochargers

•

Air Compressor and Power Steering

•

Fuel System

•


•


•

Air Intake Throttle Duct and Exhaust Manifold

•



Upper Valve Cover and Base

Figure 458 1. 2. 3. 4.

Upper valve cover and base

Screw with damper (18) M8 x 30 bolt (17) Upper valve cover Valve cover base

CAUTION: To prevent engine damage, do not use power tools to remove or install valve cover bolts. Threads will be damaged if a bolt or nut is rotated too quickly.

341

NOTE: The upper valve cover can be removed separately or as an assembly with the valve cover base depending on service work being performed. If it is being removed as an assembly, start with step 2. 1. Remove 17 M8 x 30 bolts and remove upper valve cover from base. NOTE: The valve cover base screws can only be removed from valve cover as assemblies with the dampers. The screws and dampers should only be completely removed from cover if replacing the valve cover gasket. 2. Release 18 screws with dampers from cylinder head. Do not completely remove screws from valve cover at this time. 3. Remove valve cover base (or assembly) from cylinder head. NOTE: Valve cover gaskets can be reused and do not require removal from valve cover base unless damaged.

Figure 459 1. 2. 3. 4.

Valve cover gaskets

Valve cover base Screw with damper (18) Upper valve cover gasket (Lower) valve cover gasket

4. Inspect upper and lower valve cover gaskets for damage. If damaged, replace as follows: a. Upper gasket — remove from groove in upper surface of valve cover base and discard gasket.



342

b. Lower gasket — completely remove 18 screws with dampers to release gasket from bottom of valve cover base. Discard gasket.

2. Remove 12 M12 x 60 socket-head screws. 3. Remove six rocker arm assemblies.

Rocker Arm Assembly (Non-Brake Engine) CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their orientation. Do not use paint or temporary markers.

Figure 461 bridges 1. 2.

Figure 460 1. 2.

Rocker arm assembly (typical)

M12 x 60 (socket-head) screw (12) Rocker arm assembly (6)

Rocker bearing block and valve

Rocker bearing block (6) Valve bridge (12)

4. Mark rocker bearing blocks 1 through 6 so each block can be installed in its original cylinder location. 5. Remove six rocker bearing blocks.

1. Mark rocker arm assemblies 1 through 6 so each assembly can be installed in its original cylinder location.

6. Mark valve bridges so each bridge can be installed in its original location and orientation. 7. Remove 12 valve bridges.



343

Camshaft CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their orientation. Do not use paint or temporary markers.

Figure 463 1. 2.

Figure 462

Camshaft end play check (typical)

Camshaft timing mark (typical)

Camshaft gear Timing mark

2. Turn engine crankshaft in direction of engine rotation, until timing mark on camshaft gear is aligned with cylinder head surface.

1. Check camshaft end play as follows: a. Mount dial indicator with magnetic base (page 362) on cylinder head with indicator tip on end of camshaft as shown. b. Move camshaft toward rear of engine and zero the dial indicator. c.

Move camshaft back and forth while reading dial indicator. Compare dial indicator reading with camshaft end play specification (page 361).

d. If end play exceeds specified limits, install a new camshaft.






344

3. Remove timing hole cover from lower side of flywheel housing and verify timing mark on flywheel is aligned with flywheel housing timing index. •

If timing mark on flywheel is out of alignment, then the timing has slipped due to large idler gear slippage. Install a new large idler gear. See “OIL PUMP AND TIMING GEARS” (page 398) section of this manual for procedures to replace large idler gear.

•

If timing mark on flywheel is aligned with flywheel housing timing index, continue to next step.

5. Remove seven camshaft bearing caps from the cylinder head. Mark each bearing cap with location number and orientation.

Figure 466 Camshaft bearing cap and bearing shell (typical) 1. 2. 3.

Camshaft bearing cap 4H x 8 x 10 dowel pin (2) Bearing shell

6. Remove seven bearing shells from camshaft bearing caps. Mark each bearing shell with camshaft bearing cap number and orientation. Figure 465 1. 2.

Camshaft bearing caps

Camshaft bearing cap (7) M8 x 35 bolt (14)

4. Remove 14 M8 x 35 bolts.

7. If damaged, remove 14 – 4H x 8 x 10 dowel pins from seven camshaft bearing caps. 8. Remove camshaft. 9. Remove seven lower bearing shells from cylinder head. Mark each bearing shell with camshaft bearing cap number and orientation.



345

Cylinder Head CAUTION: To prevent engine damage, remove fuel injectors before removing cylinder head. 1. Remove six fuel injectors. See Fuel Injectors in the “FUEL SYSTEM” section (page 213) of this manual for procedure to remove fuel injectors.

Figure 467 Camshaft gear and camshaft timing disc (pulse wheel) 1. 2. 3. 4.

Timing (M6 x 20 dowel) pin Camshaft gear Camshaft timing disc (pulse wheel) M8 x 30 bolt (3)

10. Remove three M8 x 30 bolts. 11. Remove camshaft timing disc and camshaft gear.

Figure 468 1. 2.

Cylinder Head Lifting Bracket

Cylinder Head Lifting Bracket M8 x 20 class 10.9 bolt (4)

12. If damaged, remove timing pin from camshaft.


346


2. Position Cylinder Head Lifting Bracket (page 362) on rear end of cylinder head. 3. Install four M8 x 20 class 10.9 bolts (page 362). Tighten bolts to standard torque (page 471).

Figure 469

Cylinder head bolts

4. Use Head Bolt Torx® Socket (page 362) and working in a circular pattern, loosen, remove and

discard 26 M18 x 246 Torx® bolts. Begin with the outer bolts and move inward.



Figure 470

Cylinder head removal

5. Lift cylinder head using a suitable lifting device. WARNING: To prevent personal injury or death, use a hoist rated for the weight of the cylinder head and follow the manufacturer’s operative and safety instructions. Attach safety lifting hooks to the cylinder head lifting bracket and lifting eye.

Figure 471

347

8 mm dowel pin (2)

9. If damaged, remove two 8 mm dowel pins.

Cylinder Head Idler Gear

CAUTION: To prevent engine damage, do not scratch gasket surface of cylinder head. CAUTION: To prevent engine damage, carefully set cylinder head on wooden blocks to protect the cylinder head idler gear. 6. Place cylinder head on a clean, non-metallic surface. 7. Remove four M8 x 20 class 10.9 bolts and Cylinder Head Lifting Bracket (page 362). 8. Remove and discard cylinder head gasket.

Figure 472

DMR 63.10 cup plug removal

1. Use a punch to knock in bottom of DMR 63.10 cup plug. Remove and discard cup plug.



348

2. Remove three M8 x 30 socket-head cap screws, small gear shaft and cylinder head idler gear.

Figure 473 1. 2. 3.

Cylinder head idler gear

Small gear shaft Cylinder head idler gear M8 x 30 socket-head cap screw (3)



Cleaning, Inspection, and Testing Cylinder Head and Crankcase Components

349

5. Clean cylinder head bolt holes in crankcase with Head Bolt Bottoming Tap (page 362). 6. Clean out debris with filtered compressed air.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). CAUTION: Do not use chlorinated solvents on cylinder head bolts. If parts are not cleaned thoroughly, parts will corrode over time. Be sure parts are clean, dry and free of chemicals other than engine oil.

Camshaft Bearings 1. With camshaft removed, install previously marked bearings and camshaft bearing caps. Tighten M8 x 35 bolts to special torque (page 361).

CAUTION: To prevent engine damage, do not scratch gasket surface of cylinder head. 1. Use a scraper and wire brush to remove deposits and gasket material from valve heads and gasket surface. 2. Use a suitable solvent to remove dirt, grease and deposits from removed parts. 3. Clean all bolt holes. Make sure gasket surfaces are clean. Clean all surfaces and ports with steam, and then dry with filtered compressed air. 4. Clean all bolts (except head bolts) with a suitable solvent and dry thoroughly. New head bolts must be installed. CAUTION: To prevent engine damage, clean and dry threads in crankcase bolt holes with filtered compressed air. Dirt or oil in holes may cause binding and incorrect torque readings.

Figure 474

Figure 475

Camshaft bearing check (typical)

2. Use a telescoping gauge set (page 362) and a 1 - 2 inch micrometer (page 362) to measure camshaft bearing inside diameter. If inside diameter does not meet specification (page 361), install new camshaft bearings.

Head bolt bottoming tap (typical)



350 Fuel Injector Bore

1. Use Injector Sleeve Brushes (page 362) in injector bore to remove deposits. WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

4. Install M8 x 50 bolt and two M8 x 100 bolts. Tighten bolts to standard torque (page 471). 5. Spray mineral spirits into exhaust ports. 6. Pour mineral spirits into air intake throttle duct until intake manifold inside cylinder head is filled.

2. Use filtered compressed air to clean out debris from injector bores.

Valves Leak Test NOTE: Position wooden blocks so the view of all the intake and exhaust valve heads and valve seat areas is not restricted. 1. Position cylinder head on wooden blocks with cylinder head gasket surface facing down.

Figure 477 1. 2. 3.

Leak inspection

Inspection mirror Reflection of valve Flashlight

NOTE: Valve seats must not leak. If valve seats leak, install a new cylinder head. Cylinder head replacement is not required if the cylinder head passes the valves leak test using mineral spirits. Figure 476 1. 2. 3.

Air intake throttle duct (typical)

M8 x 50 bolt M8 x 100 bolt (2) Air intake throttle duct

7. Wait five minutes. Use an inspection mirror to inspect valve seat area for leakage of mineral spirits. If there is no leakage of mineral spirits through the intake or exhaust valves, the cylinder head is acceptable for reinstallation.

2. Apply Loctite® 5900 sealant or equivalent (page 362) to joining surfaces of air intake throttle duct and cylinder head. 3. Install air intake throttle duct.



351

8. Position a suitable container under air intake throttle duct to catch mineral spirits. M8 x 50 bolt and two M8 x 100 bolts. 9. Remove air intake throttle duct. 10. Lift rear end of cylinder head to drain all remaining mineral spirits out of the intake manifold.

Figure 478 1. 2. 3.

Air intake throttle duct

M8 x 50 bolt M8 x 100 bolt (2) Air intake throttle duct



352

Installation Cylinder Head Idler Gear

Figure 480

Figure 479 1. 2. 3.

Cylinder head idler gear

Small gear shaft Cylinder head idler gear M8 x 30 socket-head cap screw (3)

1. Install small gear shaft and cylinder head idler gear.

DMR 63.10 cup plug installation

5. Drive new cup plug into the hole using a Bearing Installer (page 362) approximately 6 mm (0.25 in) smaller in diameter than the cup plug. 6. Recess cup plug 2.3 mm (0.9 in) below the machined surface.

Cylinder Head

2. Install three M8 x 30 socket-head cap screws. Tighten screws to special torque (page 361). 3. Clean cylinder head mating surfaces for cylinder head idler gear DMR 63.10 cup plug. 4. Apply Loctite® 262™ Threadlocker (page 362) to the outside edge of new cylinder head idler gear cup plug.

Figure 481

8 mm dowel pin (2)

1. If previously removed, install two 8 mm dowel pins in crankcase.



WARNING: To prevent personal injury or death, wear safety glasses with side shields to protect eyes. Limit compressed air pressure to 207 kPa (30 psi).

353

3. Position Cylinder Head Lifting Bracket (page 362) on rear end of cylinder head. 4. Install four M8 x 20 class 10.9 bolts (page 362). Tighten bolts to standard torque (page 471).

CAUTION: Do not use chlorinated solvents on cylinder head bolts. If parts are not cleaned thoroughly, parts will corrode over time. Be sure parts are clean, dry and free of chemicals other than engine oil. CAUTION: To prevent engine damage, clean and blow dry threads in the crankcase bolt holes with filtered compressed air. Dirt or oil in holes may cause binding or an incorrect torque reading. CAUTION: To prevent engine damage, remove debris and contaminants from cylinder head gasket mating surfaces. If debris is not removed, a faulty seal between the cylinder head, gasket and crankcase will cause oil, coolant and compression leaks. Do not apply sealant to head gasket surfaces.

Figure 483

Cylinder head installation

CAUTION: To prevent engine damage, install a new cylinder head gasket with part number facing up. 2. Install a new cylinder head gasket on crankcase, over dowel pins.

WARNING: To prevent personal injuries or death, use a hoist rated for the weight of the cylinder head and follow the manufacturer’s operation and safety instructions. Attach safety lifting hooks to the cylinder head lifting bracket and lifting eye. CAUTION: To prevent engine damage, do not drop or slide cylinder head on cylinder head gasket. This can damage the cylinder head gasket, dowel pins and the cylinder head idler gear. 5. Attach an appropriate hoist and lifting hooks to cylinder head lifting bracket and lifting eye. 6. Lower cylinder head onto crankcase and align cylinder head alignment dowels in the crankcase with dowel holes in the cylinder head.

Figure 482 1. 2.


Cylinder Head Lifting Bracket M8 x 20 class 10.9 bolt (4)


354

Figure 484


Cylinder head bolts

CAUTION: To prevent engine damage, install new cylinder head bolts when installing cylinder head. Apply a light coat of clean engine oil to new bolt threads and under bolt head. Too much oil will cause hydrostatic lock and give incorrect torque reading. Do not use anti-seize compound, grease, or any other lubricant on cylinder head bolt threads.

7. Install 26 new lightly lubricated M18 x 246 Torx® bolts. Do not tighten bolts at this time. 8. Remove four M8 x 20 class 10.9 bolts and Cylinder Head Lifting Bracket (page 362).



Figure 485

355

Cylinder head bolt tightening sequence

CAUTION: To prevent engine damage, use only permanent ink markers to identify bolt torque orientation.

3. Tighten Torx® bolts numbered 1 through 26 to 150 N·m (111 lbf·ft) in numerical sequence.

CAUTION: To prevent engine damage, use a torque wrench to tighten cylinder head bolts; do not use an impact wrench.

4. Tighten Torx® bolts numbered 1 through 26 to 300 N·m (221 lbf·ft) in numerical sequence.

NOTE: For proper cylinder head surface seating and sealing, follow the correct tightening sequence.

5. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical sequence.

9. Use Head Bolt Torx® Socket (page 362) to tighten the M18 x 246 Torx® bolts in sequence indicated above as follows: 1. Hand-tighten Torx® bolts. 2. Tighten Torx® bolts numbered 1 through 26 to 10 N·m (89 lbf·in) in numerical sequence as shown.

6. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical sequence for second time. 7. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical sequence for third time.



356 Camshaft

Figure 486 Camshaft gear and camshaft timing disc (pulse wheel) 1. 2. 3. 4.

Timing (M6 x 20 dowel) pin Camshaft gear Camshaft timing disc (pulse wheel) M8 x 30 bolt (3)

1. If previously removed, install timing (M6 x 20 dowel) pin into camshaft. 2. Align camshaft gear with timing pin and install on camshaft.

Figure 487 Camshaft lower bearing shell oil hole alignment (typical)

NOTE: If original camshaft bearings are installed, make sure to place them as previously marked in their original location and orientation. 5. Install seven new or previously marked camshaft lower bearings on cylinder head. Make sure oil holes in bearings are aligned with oil holes in cylinder head bearing support. 6. Rotate crankshaft so that cylinder number 1 is positioned at TDC.

3. Align camshaft timing disc with timing pin and install on camshaft. 4. Install and finger-tighten three M8 x 30 bolts.






7. Verify timing mark on flywheel is aligned with flywheel housing timing index at bottom of flywheel housing.

357

NOTE: Make sure that each bearing cap has the two dowel pins installed. 9. If previously removed, install 14 – 4H x 8 x 10 dowel pins into seven camshaft bearing caps. NOTE: If original bearings are installed, make sure each is placed as previously marked in its original location and orientation. 10. Install seven new or previously marked bearing shells on camshaft bearing caps.

Figure 489 1. 2.

Camshaft timing mark (typical)

Camshaft gear Timing mark

8. Lower camshaft on cylinder head and make sure timing mark on camshaft gear is aligned with cylinder head surface. Figure 491 1. 2.

Camshaft bearing caps

Camshaft bearing cap (7) M8 x 35 bolt (14)

11. Install seven previously marked camshaft bearing caps with each placed in its original location and orientation. 12. Install 14 M8 x 35 bolts. Tighten bolts to special torque (page 361).

Figure 490 shell 1. 2. 3.

Camshaft bearing cap and bearing

Camshaft bearing cap 4H x 8 x 10 dowel pin (2) Bearing shell



358

NOTE: If original valve bridges are installed, make sure each is placed as previously marked in its original location.

Figure 492 1. 2.

Camshaft gear bolts tightening

Camshaft gear M8 x 30 bolt (3)

Figure 494 13. Tighten three M8 x 30 bolts to 15 N·m (133 lbf·in). 14. Tighten three M8 x 30 bolts an additional 90° (1/4 turn).

Rocker Arm Assembly (Non-Brake Engine)

1. 2.

Valve bridge orientation (typical)

Camshaft side Exhaust manifold side

1. Place 12 new or previously marked valve bridges on intake and exhaust valves with milled end oriented toward camshaft. NOTE: If original rocker bearing blocks are installed, make sure each is placed as previously marked in its original location. 2. Install six new or previously marked rocker bearing blocks.

Figure 493 bridges 1. 2.

Rocker bearing block and valve

Rocker bearing block (6) Valve bridge (12)



359

Upper Valve Cover and Base

Figure 495 1. 2.

Rocker arm assembly (typical)

M12 x 60 (socket-head) screw (12) Rocker arm assembly (6)

NOTE: If original rocker arm assemblies are installed, make sure each is placed as previously marked in its original location. 3. Install six new or previously marked rocker arm assemblies. 4. Install 12 M12 x 60 socket-head screws. Tighten screws to special torque (page 361). 5. Adjust valve lash. See procedure (Valve Lash Adjustment, page 337) in this section.

Figure 496 1. 2. 3. 4.

Valve cover gaskets

Valve cover base Screw with damper (18) Upper valve cover gasket (Lower) valve cover gasket

1. If necessary, install a new upper and/or lower valve cover gasket. 2. If previously removed, install 18 screws with dampers in valve cover base and through valve cover base gasket.



360

CAUTION: To prevent engine damage, do not use power tools to remove or install valve cover bolts. Threads will be damaged if a bolt or nut is rotated too quickly. 3. Place valve cover base on cylinder head. 4. Tighten 18 screws with dampers to special torque (page 361). 5. If removed, place upper valve cover on valve cover base. 6. Install 17 M8 x 30 bolts and tighten to special torque (page 361).

Figure 497 1. 2. 3. 4.

Upper valve cover and base

Screw with damper (18) M8 x 30 bolt (17) Upper valve cover Valve cover base



361


Cylinder Head, Camshaft and Valve Train

Camshaft Camshaft bearing inside diameter Camshaft end play

39.925 – 39.950 mm (1.57185 – 1.57283 in) 0.25 – 0.85 mm (0.0098 – 0.0334 in)

Valve Lash Adjustment Exhaust valve clearance

0.8 mm (0.0315 in)

Intake valve clearance

0.5 mm (0.0197 in)

Cylinder Head Idler Gear Cup Plug Cup plug, DMR 63.10

Recess 2.3 mm (0.9 in)



Camshaft gear M8 x 30 bolt


(Camshaft) bearing cap M8 x 35 bolt

25 N·m (18 lbf·ft)

Cylinder head idler gear M8 x 30 socket-head cap screw

30 N·m (22 lbf·ft)

Cylinder head M18 x 246 Torx® bolt Rocker arm assembly M12 x 60 (socket-head) screw

See tightening steps in procedure 105 N·m (77 lbf·ft)

Upper valve cover M8 x 30 bolt

10 N·m (89 lbf·in)

Valve cover base screw with damper

11 N·m (97 lbf·in)

Valve lash adjustment M10 nut

45 N·m (33 lbf·ft)



362



Description

Tool Number

1 - 2 inch micrometer

Obtain locally

Bearing installer

Obtain locally


ZTSE4869

Dial indicator with magnetic base

Obtain locally

Feeler gauge (standard)

Obtain locally

Feeler gauge (Jacobs® 96-020949)

Obtain from Jacobs

Head Bolt Bottoming Tap

ZTSE4855

Head Bolt Torx® Socket

ZTSE4835


ZTSE4751

™

Loctite® 262 Threadlocker

Obtain locally

Loctite® 5900 sealant or equivalent

Obtain locally

M8 x 20 class 10.9 bolts

Obtain locally

Telescoping gauge set

Obtain locally


FLYWHEEL AND FLYWHEEL HOUSING

363

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368 Preliminary Checks and Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368 Flywheel Assembly (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368 Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368 Pilot Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369 Flywheel (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369 Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369 Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 All Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 Flywheel and Flexplate Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 Recondition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374 Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374 Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375 Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376 Flywheel Assembly (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376 Pilot Bearing (Flywheel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377 Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379


364




Exploded Views

Figure 498 1. 2. 3. 4. 5.

Flywheel housing and flywheel (manual transmission)

Radial shaft ring seal M10 x 30 bolt (12) M10 x 40 bolt (3) Flywheel housing 56/48 x 19 plug (converter bolt access)

6. 7. 8. 9. 10. 11.

Dowel pin (2) Timing hole cover Tapping screw (2) Plug Flywheel assembly Pilot bearing

12. 12PT flange bolt (10) 13. M16 x 150 bolt (4) 14. Lifting eye (2)


365


366

Figure 499 1. 2.

Flywheel and flexplate assembly (automatic transmission)

12PT flange bolt (10) Wear plate (reinforcement ring)

3. 4.

Flexplate assembly Flywheel assembly

5.

8 x 60-ST pin



Figure 500 1. 2. 3.

367

Rear engine mounts

Left offset engine mounting support Extension assembly PDO base bracket

4. 5. 6.

3/4” x 2” bolt (12) Right offset engine mounting support Flywheel housing

7.

3/4” washer (12)



368

Removal

3. Inspect all ring gear teeth for starter pinion damage. 4. Replace flywheel if necessary.


Flywheel Surface Runout CAUTION: To prevent engine damage, check runout of flywheel surface for correct alignment of engine to transmission. Failure to ensure correct bore concentricity and face runout may reduce life of clutch or transmission.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. NOTE: Refer to the following service section for information on removal of components prior to this section. •


Preliminary Checks and Measurements Flywheel Assembly (Manual Transmission) 1. Inspect flywheel for cracks around webbing and bolt holes. 2. Inspect flywheel for heat cracks and extensive scoring.

Figure 501 1. 2.

Flywheel surface runout

Dial indicator with magnetic base Flywheel

1. Attach dial indicator with magnetic base (page 379) to surface of lifting eye. Place indicator tip against flywheel. NOTE: Keep crankshaft end play at zero and rotate in same direction for all measurements. 2. Push the flywheel inward to eliminate crankshaft end play, zero dial indicator. 3. While pushing inward on the flywheel to eliminate crankshaft end play, slowly rotate crankshaft one complete revolution. Compare total dial indicator variation (highest - lowest reading) to flywheel maximum surface run out specification (page 379).


FLYWHEEL AND FLYWHEEL HOUSING Pilot Bearing

369

1. Remove transmission and torque converter assembly. (See transmission manufacturer’s service publications.) 2. Remove and discard two 12PT flange bolts at approximately 3 o’clock and 9 o’clock position. 3. Install two guide pins (make locally) into crankshaft flange. 4. Remove and discard remaining eight 12PT flange bolts. 5. Slide wear plate (reinforcement ring) and four flexplates off guide pins. 6. Slide flywheel assembly off guide pins and out of flywheel housing. 7. Remove guide pins from crankshaft flange.

Figure 502 1. 2.

Pilot bearing removal (typical)

Slide hammer and blind hole puller Pilot bearing

Flywheel and Flexplate Assembly (Automatic Transmission)

1. Using a slide hammer (page 379), install blind hole puller (page 379), into pilot bearing. 2. Tap slide hammer and remove pilot bearing.

Flywheel (Manual Transmission)

Figure 504

Figure 503 1. 2.

Flywheel removal

12PT flange bolt (10) Flywheel assembly

1. 2. 3. 4.

Flywheel and flexplate assembly

Flexplate and flywheel assembly 12PT flange bolt (10) Guide pin (2) Wear plate (reinforcement ring)



370

1. Remove transmission and torque converter assembly. (See transmission manufacturer’s service publications.) 2. Remove and discard two 12PT flange bolts, 180 degrees from each other (approximately 3 o’clock and 9 o’clock positions). 3. Install two guide pins (made locally) in place of two removed 12PT flange bolts. 4. Remove and discard the remaining eight 12PT flange bolts.

1. With an awl and hammer, punch two holes 180° apart in radial shaft ring seal. 2. Thread a slide hammer (page 379) with correct size screw into one of the two holes. 3. Slide hammer until one side of seal begins to pull out of flywheel housing. Move slide hammer to other hole and repeat until seal is completely removed.

Lifting Eyes

NOTE: The individual components of the flexplate assembly are non-servicable. Replace the flexplate as an assembly. 5. Slide wear plate (reinforcement ring) and four flexplates off guide pins. 6. Slide flywheel assembly off guide pins and out of flywheel housing. 7. Remove guide pins from crankshaft flange.

Radial Shaft Ring Seal WARNING: To prevent personal injury or death, wear safety glasses with side shields. Figure 506 1. 2.

Lifting eye

M16 x 150 bolt (4) Lifting eye (2)

1. Remove four M16 x 150 bolts. 2. Remove two lifting eyes.

Flywheel Housing

Figure 505 1. 2.

Radial shaft ring seal removal

Slide hammer Radial shaft ring seal

WARNING: To prevent personal injury or death, support the flywheel housing before removing bolts and breaking sealant bond between flywheel housing and crankcase. WARNING: To prevent personal injury or death, get help when removing or installing the flywheel housing.



Figure 508 Figure 507 Right offset engine mounting support assembly 1. 2. 3. 4.

Right offset engine mounting support PDO base bracket Flywheel housing 3/4" x 2” bolt with 3/4” washer (6)

1. Remove six 3/4" x 2” bolts with washers, PDO base bracket and engine mounting support from right side of flywheel housing. 2. Remove 3/4" x 2” bolts with washers, extension bracket and engine mounting support from the left side of flywheel housing.

1. 2. 3.

371

Flywheel housing (typical)

M10 x 30 bolt (12) M10 x 40 bolt (3) Flywheel housing

WARNING: To prevent personal injury or death, support the flywheel housing before removing bolts and breaking sealant bond between housing and crankcase. 3. Remove 12 M10 x 30 and three M10 x 40 bolts from flywheel housing. 4. Use a thin gasket scraper to separate sealant between flywheel housing and crankcase. WARNING: To prevent personal injury or death, get help when removing or installing the flywheel housing. 5. Remove flywheel housing with aid of an assistant.



372

Cleaning and Inspection All Components

WARNING: To prevent personal injury or death, do not machine flywheel beyond minimum thickness specified for flywheel resurfacing.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 1. Clean foreign material from gasket surfaces of crankcase and flywheel housing. Use a scraper or wire brush to remove sealant from gasket surfaces. 2. Gasket surfaces must be oil-free for good adhesion of liquid gasket during assembly. Use a commercially available, non-caustic brake cleaner to clean gasket surfaces of crankcase and flywheel housing. 3. Wash flywheel, flexplate (if equipped) and flywheel housing. Dry all with filtered compressed air. 4. Wash crankshaft timing gear with a stiff brush and suitable solvent. Dry all with filtered compressed air.

Flywheel and Flexplate Assemblies 1. Inspect flywheel for cracks around webbing and bolt holes. 2. Inspect flywheel for extensive heat cracks and scoring. 3. If equipped, inspect flexplate for cracks, damage or warpage. Replace if required. 4. Inspect all ring gear teeth for starter pinion damage. 5. Replace flywheel if necessary.

Recondition Flywheel NOTE: Flywheels used with manual transmissions may be resurfaced to correct minor wear and scoring. If flywheel meets the following requirements it can be resurfaced.

Figure 509 1. 2. 3.

Flywheel surface dimension (typical)

Flywheel thickness (dimension “A”) Clutch disc mounting face Crankshaft timing gear face

NOTE: Flywheel resurfacing information is provided for guidance only. Navistar, Inc. assumes no responsibility either for the results of any work performed in accordance with this information or for the ability of service personnel to detect cracks. WARNING: To prevent personal injury or death, carefully examine flywheel for any cracks or heat checks before and after resurfacing. Cracks in the flywheel can cause it to separate. If there are any questions, do not reuse the flywheel.



373

1. Check flywheel for cracks and damage. Replace flywheel if required.

4. Check flywheel for cracks and damage after resurfacing. Replace flywheel if required.

2. Using 1-2 inch micrometer (page 379), measure flywheel thickness and compare to minimum required thickness specification (dimension “A”) (page 379). Discard flywheel if below minimum thickness specification or if flywheel will be below minimum thickness after resurfacing.

5. Measure flywheel thickness after resurfacing and compare to minimum required thickness specification. Discard flywheel if below minimum thickness specification.

3. Resurface flywheel. See Flywheel Resurfacing Machine operators manual for instructions on flywheel resurfacing procedure.



374

Installation Flywheel Housing CAUTION: To prevent engine damage, apply Liquid Gasket and component within 5 minutes of application to inhibit the formation of a skin and ensure a leak proof joint.

Figure 511 1. 2.

Figure 510 Flywheel housing to crankcase alignment dowel pins 1. 2.

Flywheel housing to crankcase mating surface Flywheel housing to crankcase dowel pin (2)

1. Verify flywheel housing alignment dowels are installed into the crankcase and are not damaged. Replace as necessary.

Flywheel housing sealant application

Apply sealant on mating surface Front of flywheel housing

2. Apply Loctite 5900 or Wacker® A–442 RTV sealant (page 379) to mating surfaces of flywheel housing and crankcase. WARNING: To prevent personal injury or death, get help when removing or installing the flywheel housing. 3. Install flywheel housing to crankcase with the aid of an assistant.



375

5. Install 3/4" x 2” bolts, washer, extension bracket and rear engine mount on left side of flywheel housing. Tighten to standard torque (page 471). 6. Install 3/4" x 2” bolts, washer, PDO base bracket and engine mounting support on right side of flywheel housing. Tighten to standard torque (page 471).

Lifting Eyes

Figure 512 1. 2. 3.

Flywheel housing (typical)

M10 x 30 bolt (12) M10 x 40 bolt (3) Flywheel housing

4. Install 12 M10 x 30 and three M10 x 40 flywheel housing bolts. Tighten bolts to special torque (page 379).

Figure 514 1. 2.

Lifting eyes

M16 x 150 bolt (4) Lifting eye (2)

1. Install two lifting eyes. 2. Install four M16 x 150 lifting eye bolts. Tighten bolts to special torque (page 379).

Figure 513 Right offset engine mounting support assembly 1. 2. 3. 4.

Right offset engine mounting support PDO base bracket Flywheel housing 3/4" x 2” bolt with 3/4” washer (6)



376 Radial Shaft Ring Seal


Radial shaft ring seal installation Figure 516

Rear Oil Seal Installer Radial shaft ring seal

CAUTION: To avoid damage to the radial shaft ring seal, do not touch inner seal lip or allow oil or grease on any part of the seal during installation. 1. Using Rear Oil Seal Installer (page 379), install ring radial shaft seal into flywheel housing. a. Install inner hub of tool to crankshaft flange. Use two bolts provided with tool. b. Install radial shaft seal to inner hub of tool. c.

Install pressing hub and nut and tighten to install seal. When tool bottoms out, seal is fully installed.

Flywheel Assembly (Manual Transmission)

1. 2. 3.

Flywheel assembly and bolts

12PT flange bolt (10) Flywheel assembly 8 x 60-ST pin

2. Align crankshaft timing gear pin hole in flywheel assembly with crankshaft timing gear pin and slide flywheel onto guide pins. CAUTION: To prevent engine damage, always install new flywheel mounting bolts. CAUTION: To prevent engine damage, do not use anti-seize compounds or grease on new flywheel or flexplate mounting bolts. 3. Loosely install eight new 12PT flange bolts to secure flywheel assembly to crankshaft. 4. Remove both guide pins and loosely install two remaining new 12PT flange bolts.

1. Install two guide pins (made locally) into crankshaft flange at approximately 3 o’clock and 9 o’clock position.



377

2. Using Pilot Bearing Installation Tool (page 379), tap pilot bearing into flywheel. When tool bottoms out, pilot bearing is fully installed.

Flywheel and Flexplate Assembly (Automatic Transmission)

Figure 517

Flywheel bolt tightening sequence

NOTE: For proper flywheel installation, follow the correct tightening sequence while keeping the crankshaft from turning. 5. Tighten 12PT flange bolts using sequence indicated above as follows: a. Tighten bolts to 110 N·m (81 lbf·ft). b. Angle tighten bolts 90°. c.

Angle tighten bolts an additional 90°. Figure 519

Pilot Bearing (Flywheel)

1. 2. 3. 4.

Flywheel and flexplate assembly

Flexplate and flywheel assembly 12PT flange bolt (10) Guide pin (2) Wear plate (reinforcement ring)

1. Install two guide pins (made locally) into crankshaft flange 180° apart (approximately 3 o’clock and 9 o’clock positions). 2. Align crankshaft timing gear pin hole in flywheel assembly with crankshaft gear pin and slide flywheel onto guide pins. CAUTION: To prevent engine damage, always install new flywheel mounting bolts.

Figure 518

Pilot Bearing Installation Tool

1. Place pilot bearing in flywheel bore.

CAUTION: To prevent engine damage, do not use anti-seize compounds or grease on new flywheel or flexplate mounting bolts. NOTE: The individual components of the flexplate assembly are non-servicable. Replace the flexplate as an assembly.


378


3. Slide flexplate assembly over guide pins. 4. Slide wear plate (reinforcement plate) over guide pins with logo and part number visible towards rear and install eight new 12PT flange bolts hand tight. 5. Remove guide pins and install remaining two 12PT flange bolts.

NOTE: For proper flywheel installation, follow the correct tightening sequence while keeping the crankshaft from turning. 6. Tighten 12PT flange bolts using sequence above as follows: a. Tighten bolts to 110 N•m (81 lbf·ft). b. Angle tighten bolts 90° c.

Angle tighten bolts an additional 90°.

Figure 520 Flywheel and flexplate assembly bolt tightening sequence (typical)



379


Flywheel and Flywheel Housing

Flywheel minimum thickness (dimension “A”) Flywheel maximum surface runout

46 mm (1.811 in) 0.20 mm (0.0079 in)



12PT flange bolts Flywheel housing bolts, M10 x 30 and M10 x 40 Lifting eye bolts, M16 x 150 Timing hole cover screws

See tightening steps in procedure. 65 N·m (48 lbf·ft) 280 N·m (207 lbf·ft) 2 N·m (18 lbf·in)



Description

Tool Number

1-2 inch micrometer

Obtain locally

Blind hole puller

Obtain locally

Brake cleaner (non-caustic)

Obtain locally


Obtain locally

Loctite 5900®

Obtain locally

Wacker® A–442 RTV sealant

Obtain locally


ZTSE4898

Rear Oil Seal Installer

ZTSE4875

Slide hammer

Obtain locally


380



OIL PAN AND OIL PICKUP TUBE

381

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385 Oil Pickup Tube — Front Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386 Oil Pickup Tube — Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388 Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389 Oil Pickup Tube — Front Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389 Oil Pickup Tube — Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392


382




383

Exploded Views

Figure 521 1. 2. 3. 4.

Oil pan (front sump shown, rear sump similar, typical)

Oil pan gasket Oil pan (front sump) O-ring (heater, optional equipment) Oil pan heater element (optional equipment)

5. 6. 7.

Oil pan clamp (concave groove) (6) Oil pan clamp (convex groove) (16) Cooling tube bracket (2) (right angle)

8. 9.

M8 x 40 bolt (22) Extension bracket support (T-bracket) 10. Oil drain M27 x 2 plug 11. O-ring (32.92 x 3.53)



384

Figure 522 1. 2. 3.

Oil pickup tube - Front sump (typical)

O-ring, 32 x 5 Prevailing torque nut (M8) (2) D9/19/4 washer (2)

4. 5. 6.

Oil pickup tube support (2) M8 x 25 bolt (2) Pickup oil tube

7.

M8 x 16 bolt (2)




385

2. If equipped, remove oil pan heater element and discard O-ring. 3. Recycle or dispose of oil according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual. WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set the parking brake, and block the wheels before doing diagnostic or service procedures. WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components.

Figure 523 1. 2. 3.

Oil pan (front sump shown)

M8 x 40 bolt (22) Cooling tube bracket (right angle) (2) Extension bracket support (T-bracket)

NOTE: Record style and location of brackets for correct placement during installation. 4. Remove 22 M8 x 40 bolts and three brackets.

WARNING: To prevent personal injury or death, remove the ground cable from the negative terminal of the main battery before disconnecting or connecting electrical components. Always connect the ground cable last. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. NOTE: Refer to the following service section for information on removal of components prior to this section. •

Engine Electrical — required for preheater removal.

Figure 524 1. 2.

Oil Pan

Oil pan retainers

Oil pan clamps (concave groove) (6) Oil pan clamps (convex groove) (16)

1. Remove oil drain plug and gasket and drain oil into a suitable container. 5. Remove six oil pan clamps (concave groove). EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved


386

6. Remove 16 oil pan clamps (convex groove). 7. Remove oil pan and oil pan gasket as an assembly. 8. Clean and inspect the oil pan gasket. Discard gasket if damaged.

1. Remove two M8 x 16 bolts and pickup tube with supports as an assembly. 2. Only if required, remove the two M8 x 25 bolts, prevailing torque nuts, D9/19/4 washers and oil pickup tube supports.

Oil Pickup Tube — Front Sump

Figure 526

Figure 525 1. 2. 3.

Oil pickup tube (front sump, typical)

Oil pickup tube O-ring

3. Remove and discard oil pickup tube O-ring.

M8 x 25 bolt (2) Oil pickup tube M8 x 16 bolt (2)


OIL PAN AND OIL PICKUP TUBE Oil Pickup Tube — Rear Sump

387

2. Remove oil pickup tube and supports as an assembly. 3. Only if required, remove M8 x 25 bolts, prevailing torque nuts and D9/19/4 washers and supports.

Figure 527 1. 2. 3. 4.

Oil pickup tube (rear sump)

M8 x 16 bolt (4) M8 x 25 bolt (3) Oil pickup tube Tube support

Figure 528


4. Remove and discard oil pickup tube O-ring.

1. Remove four M8 x 16 bolts holding oil pickup tube supports to crankcase.


388


Cleaning and Inspection WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

4. Inspect oil pan for warping, dents and cracks. Replace the oil pan if necessary.

Oil Pickup Tube 1. Clean oil pickup tube and supports with a suitable solvent.

Oil Pan 1. Inspect bottom of oil pan for metallic debris or other evidence of engine damage. Investigate any abnormalities as required. 2. Clean oil pan with a suitable solvent.

2. Dry with filtered compressed air. 3. Inspect oil pickup tube and supports for cracks, damage or pickup screen blockage. Replace if necessary.

3. Dry with filtered compressed air.



Installation Oil Pickup Tube — Front Sump

389

2. If required, position two oil pickup tube supports and loosely install two M8 x 25 bolts, prevailing torque nuts and D9/19/4 washers. 3. Install oil pickup tube and two M8 x 16 bolts. 4. Tighten two M8 x 16 bolts to standard torque (page 471). 5. Tighten two prevailing torque nuts (M8) and M8 x 25 bolts to standard torque (page 471).

Oil Pickup Tube — Rear Sump 1. Lubricate a new oil pickup tube O-ring with clean engine oil and install onto tube.

Figure 529


1. Install a new oil pickup tube O-ring. Lubricate O-ring with clean engine oil.

Figure 531 1. 2. 3. 4. 5. 6. 7.

Figure 530 1. 2. 3.

Rear sump oil tube assembly

O-ring, 32 x 5 Prevailing torque nut (4) D9/19/4 washers (4) Supports (short) (3) M8 x 25 bolt (4) Support (long) Oil pickup tube

Oil pickup tube (front sump, typical)

M8 x 25 bolt (2) Oil pickup tube M8 x 16 bolt (2)

2. If oil pickup tube supports were removed, loosely install with four M8 x 25 bolts, D9/19/4 washers and prevailing torque nuts. 3. Install oil pickup tube and supports as an assembly.



390

Figure 533 Figure 532 1. 2. 3. 4.

Oil pickup tube

M8 x 16 bolts (4) M8 x 25 bolts (3) Oil pickup tube Tube support

1. 2.

Oil pan clamps

Oil pan clamp (concave groove) (6) Oil pan clamp (convex groove) (16)

3. Install an oil pan clamp (concave groove) and a M8 x 40 bolt in each corner of the oil pan. Finger-tighten each bolt.

4. Install four M8 x 16 bolts through oil pickup tube supports. 5. Tighten four M8 x 16 bolts to standard torque (page 471). 6. Tighten three M8 x 25 bolts and prevailing torque nuts to standard torque (page 471).

Oil Pan 1. Install oil pan gasket on oil pan. 2. Position oil pan and oil pan gasket as an assembly on the crankcase. Figure 534 1. 2. 3.

Oil pan (front sump, typical)

M8 x 40 bolt (22) Cooling tube bracket (right angle bracket) (2) Extension bracket support (T-bracket)

4. Position three brackets on oil pan clamps in original locations. 5. Install the remaining clamps and M8 x 40 bolts. Finger-tighten each bolt.



Figure 535

391

Oil pan bolt torque sequence

6. Follow the torque sequence and tighten 22 M8 x 40 bolts to special torque (page 392).

lubricated with clean engine oil. Tighten plug to special torque (page 392).

7. Re-torque 22 M8 x 40 bolts to special torque (page 392).

9. Lubricate a new oil pan drain plug O-ring with clean engine oil and put O-ring on the M27 x 2 drain plug.

8. If equipped with oil pan heater element, lubricate a new O-ring with clean engine oil and install element and lubricated O-ring into the oil pan. Tighten element to special torque (page 392).

10. Install M27 x 2 drain plug and tighten to special torque (page 392).

On vehicles not equipped with an oil pan heater element, install drain plug with a new O-ring




Oil Pan Components

Drain plug, M27 x 2

75 N·m (55 lbf·ft)

Oil pan bolts, M8 x 40

35 N·m (26 lbf·ft)

Oil pan heater element or replacement drain plug

75 N·m (55 lbf·ft)


OIL PUMP AND TIMING GEARS

393

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398 Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398 Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399 Front Crank Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403 Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403 Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404 Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404 Front Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406 Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408


394




395

Exploded Views

Figure 536 1. 2. 3.

Oil pump

M6 x 20 bolt (8) Oil pump cover Pinion (gear) for oil pump

4. 5. 6.

(Oil pump) ring gear M10 x 35 socket-head cap screw Spring pin 4 x 14 ST

7. 8. 9.

Axle for pinion (oil pump) O-ring 22 x 2 O-ring 25.12 x 1.78



396

Figure 537 1. 2.

Front timing gears (typical)

(Front) idler gear Gear stud (not flywheel side)

3.

M12 x 50 socket-head cap screw (3)

4.

Front crank gear



Figure 538 1. 2. 3. 4.

397

Rear timing gears

M8 x 30 socket-head cap screw (3) Gear stud small Crankcase idler gear Thrust washer (for gear stud air compressor)

5. 6. 7. 8. 9.

Air compressor coupled idler gear assembly Air compressor gear stud M12 x 55 bolt (3) Rear crank gear assembly Small idler gear

10. Large idler gear 11. Gear stud big 12. M14 x 80 bolt (4)



398

Removal

Preliminary Checks



Figure 539 (Front) idler gear backlash measurement (typical)

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures.

1. Rotate engine and look for any damaged gear teeth. Replace damaged gears as necessary.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components.

2. Place dial indicator with magnetic base (page 408) on front of crankcase with indicator tip on front idler gear. Position dial indicator tangent (90°) relative to plane of gear tooth.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids. NOTE: Refer to the following service sections for information on removal of components prior to this section. •


•


•


3. Turn front idler gear clockwise and zero dial indicator. 4. Turn front idler gear back and forth while reading dial indicator. Compare dial indicator reading with Specifications (page 408). 5. If front idler gear backlash exceeds specification, replace gear.



399

10. Place dial indicator with magnetic base (page 408) on top rear of crankcase with indicator tip on crankcase idler gear. Position dial indicator tangent (90°) relative to plane of gear tooth. 11. Turn crankcase idler gear clockwise and zero dial indicator. 12. Turn crankcase idler gear back and forth while reading dial indicator. Compare dial indicator reading with Specifications (page 408). 13. If crankcase idler gear backlash exceeds specification, replace crankcase idler gear.

Figure 540 (Rear) large idler gear backlash measurement (typical)

Oil Pump

6. Place dial indicator with magnetic base (page 408) on rear of crankcase with indicator tip on large idler gear tooth. Position dial indicator tangent (90°) relative to plane of gear tooth. 7. Turn large idler gear clockwise and zero dial indicator. 8. Turn large idler gear back and forth while reading dial indicator. Compare dial indicator reading with Specifications (page 408). 9. If backlash exceeds specification, replace large idler gear. Figure 542 1. 2.

Oil pump cover (typical)

M6 x 20 bolt (8) Oil pump cover

1. Remove eight M6 x 20 bolts. 2. Remove oil pump cover. 3. Remove and discard O-ring.

Figure 541 Crankcase idler gear backlash measurement (typical)



400

Figure 543 1. 2. 3.

Oil pump pinion (gear) and ring gear

(Oil pump) ring gear Oil pump pinion (gear) Marks for reassembly (towards front)

CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their orientation. Do not use paint or temporary markers. 4. Use a permanent marker to mark the front of oil pump pinion (gear) and ring gear for correct assembly orientation. 5. Remove oil pump pinion gear and ring gear.

Figure 544 1. 2. 3.

(Oil pump) pinion axle

M10 x 35 socket-head cap screw (Oil pump) pinion axle O-ring 22 x 2

6. Remove M10 x 35 socket-head cap screw and oil pump pinion axle. 7. Remove and discard O-ring 22 x 2. Front Crank Gears

Figure 545

Front crank gear (typical)

1. Using a gear puller (page 408), remove front crank gear. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved


401

1. Remove four M14 x 80 bolts, big gear stud and idler gear assembly.

Figure 546 1. 2. 3.

(Front) idler gear (typical)

M12 x 50 socket-head cap screw (3) Gear stud (front idler) Idler gear

2. Remove three M12 x 50 cap screws, gear stud and idler gear.

Rear Timing Gears

Figure 547 marks 1. 2. 3. 4. 5.

Idler gear assembly and timing

M14 x 80 bolt (4) Big gear stud Large idler gear Timing mark (large idler gear) Timing mark (rear crank gear)

Figure 548 1. 2. 3.

Crankcase idler gear (typical)

M8 x 30 socket-head cap screw (3) Small gear stud Crankcase idler gear

2. Remove three M8 x 30 cap screws, small gear stud and crankcase idler gear.

Figure 549 1. 2.

Rear crank gear assembly (typical)

Rear crank gear Pin 8 x 60-ST

3. Using a gear puller (page 408), remove rear crank gear assembly.


402


4. Remove three M12 x 55 bolts and air compressor gear stud, air compressor idler gear assembly and thrust washer for air compressor gear stud (not shown, behind gear assembly).

Figure 550 Air compressor coupled idler gear assembly (typical) 1. 2. 3.

M12 x 55 bolt (3) Air compressor gear stud Air compressor idler gear assembly



403

Cleaning and Inspection Timing Gears WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). 1. Wash timing gears and gear pins with a stiff brush and suitable solvent. Dry all with filtered compressed air. 2. Inspect timing gears for irregular wear pattern and worn or damaged teeth. Replace as necessary. 3. Inspect timing gear shafts for worn or damaged bearing surfaces. Replace as necessary.

Figure 551 Pinion (gear) for oil pump and ring gear end play measurement (typical)

Oil Pump 1. Wash all parts thoroughly in a suitable solvent. 2. Dry with filtered compressed air.

6. Using a feeler gauge (page 408), measure end play between oil pump cover and oil pump gears.

3. Inspect pinion (gear) for oil pump, oil pump ring gear and oil pump cover for nicks, burrs or scoring.

NOTE: There are two oil pump assemblies. When replacing oil pump parts, be sure you are ordering the correct set.

4. Replace any damaged components.

7. If end play exceeds specification (page 408), replace oil pump cover, pinion (gear) for oil pump and ring gear as a set.

5. Temporarily install oil pump components (page 406) in crankcase without O-ring and tighten M6 x 20 bolts to standard torque (page 471).

8. Remove oil pump components for final assembly.



404

Installation Rear Timing Gears

Figure 553 (typical) Figure 552 Air compressor coupled idler gear assembly (typical) 1. 2. 3.

M12 x 55 bolt (3) Air compressor gear stud Air compressor idler gear assembly

Crankshaft alignment pin hole

3. Rotate crankshaft so that alignment pin hole is at 6 o’clock position. This positions cylinder No. 1 at Top Dead Center (TDC).

CAUTION: To prevent engine damage, install thrust washer for air compressor gear stud with larger chamfer side facing crankcase. 1. Install air compressor thrust washer (with larger chamfer side facing crankcase), air compressor gear stud and air compressor coupled idler gear assembly. 2. Install three M12 x 55 bolts. special torque (page 408).

Tighten bolts to

Figure 554 1. 2.

Rear crank gear assembly (typical)

Rear crank gear Pin 8 x 60-ST

WARNING: To prevent personal injury or death, wear safety glasses with side shields. 4. Using a hammer and brass drift, install rear crank gear so pin in gear engages crankshaft alignment pin hole.



Figure 555 1. 2. 3.

Crankcase idler gear (typical)

M8 x 30 socket-head cap screw (3) Small gear stud Crankcase idler gear

CAUTION: To prevent engine damage, insert the crankcase idler gear into the crankcase with the flatter contact surface facing outwards. 5. Install crankcase idler gear and small gear stud. 6. Install three crankcase idler gear M8 x 30 socket-head cap screws. Tighten cap screws to special torque (page 408).

Figure 556 marks 1. 2. 3. 4. 5.

405

Large Idler gear assembly and timing

M14 x 80 bolt (4) Big gear stud Large idler gear Timing mark (large idler gear) Timing mark (rear crank gear)

NOTE: Large idler gear has two timing marks 180° apart; either may be used. 7. Install big gear stud and large idler gear, aligning timing mark with timing mark on rear crank gear (flywheel side). 8. Install four M14 x 80 bolts. Tighten bolts to special torque (page 408).



406 Front Timing Gears

3. Install two suitable alignment bolts 180° apart through front crank gear into front of crankshaft. WARNING: To prevent personal injury or death, wear safety glasses with side shields. 4. Using a hammer and brass drift, carefully install front crank gear. 5. Remove two alignment bolts.

Oil Pump 1. Lubricate new O-ring 22 x 2 with clean engine oil and install oil pump pinion axle.

Figure 557 1. 2. 3.

(Front) idler gear (typical)

M12 x 50 socket-head cap screw (3) Gear stud (not flywheel side) Idler gear

1. Install idler gear and gear stud. 2. Install three front idler gear M12 x 50 cap screws. Tighten screws to special torque (page 408).

Figure 559 1. 2. 3.

Figure 558

Front crank gear (typical)

Pinion axle (oil pump)

M10 x 35 socket-head cap screw Pinion axle (oil pump) O-ring 22 x 2

2. Install oil pump pinion axle and M10 x 35 cap screw. Tighten screw to special torque (page 408).



407

5. Lubricate new oil pump cover O-ring with clean engine oil and install on cover.

Figure 560 gear 1. 2. 3.

Pinion (gear) for oil pump and ring

(Oil pump) ring gear Pinion (gear) for oil pump Marks for reassembly (toward front)

Figure 561 1. 2.

Oil pump cover (typical)

M6 x 20 bolt (8) Oil pump cover

3. Lubricate pinion (gear) for oil pump and ring gear with clean engine oil.

6. Install oil pump cover.

4. Install pinion gear and ring gear with previously made index marks facing towards front.

7. Install eight M6 x 20 bolts. standard torque (page 471).

Tighten bolts to



408 Specifications Table 37

Oil Pump and Timing Gears

Front Timing Gears (Front) idler gear backlash

0.057 - 0.183 mm (0.0022 - 0.0072 in)

Oil Pump Oil pump pinion (gear) and ring gear end play

0.030 - 0.120 mm (0.0012 - 0.0047 in)

Rear Timing Gears Idler larger gear backlash

0.052 - 0.176 mm (0.0020 - 0.0069 in)

Large idler gear backlash

0.052 - 0.176 mm (0.0020 - 0.0069 in)



Air compressor coupled idler gear, M12 x 55 bolts Crankcase idler gear, M8 x 30 socket-head cap screws (Front) idler gear, M12 x 50 socket-head cap screws Larger idler gear, M14 x 80 bolts Oil pump pinion axle, M10 x 35 socket-head cap screw

107 N·m (79 lbf·ft) 30 N·m (22 lbf·ft) 105 N·m (77 lbf·ft) 175 N·m (129 lbf·ft) 65 N·m (48 lbf·ft)



Description

Tool Number


Obtain locally

Feeler gauge

Obtain locally

Gear puller

Obtain locally


POWER CYLINDERS

409

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413 Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413 Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414 Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415 Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417 Piston Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417 Piston Ring Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418 Connecting Rod Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418 Connecting Rod Bore Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419 Piston Pin Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419 Cylinder Sleeve Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421 Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421 Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421 Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .422 Engine Run-in Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427


410

POWER CYLINDERS


POWER CYLINDERS

411

Exploded Views

Figure 562 1. 2. 3. 4. 5. 6.

Piston and connecting rod (typical)

Compression top ring (6) Taper face compression ring (6) Bevelled oil ring (6) Piston (6) Piston pin retainer (12) Piston pin (6)

7.

Connecting rod assembly (6) (includes items 8, 9, 10) 8. Connecting rod 9. Connecting rod cap 10. Connecting rod bolt (2 each assembly)

11. Connecting rod bearing, lower (6) 12. Connecting rod bearing, upper (6) 13. Front of engine


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412

Figure 563 1.

Cylinder sleeve

Cylinder sleeve (6)

2.

Cylinder sleeve O-ring (12)


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Removal

413

NOTE: Refer to the following service sections for information on removal of components prior to this section.


•

Engine Electrical

•

Cold Start Assist

•


•

MaxxForce® Engine Brake by Jacobs

•

Turbochargers

•

Fuel System

•



•


•


•



•

Flywheel and Flywheel Housing (as needed)

•

Oil Pan and Oil Suction Tube

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components.


Preliminary Checks NOTE: Evaluate piston protrusion before removing any piston and connecting rod assemblies. This helps identify bent or twisted connecting rods.


Figure 564

Piston protrusion check

NOTE: Piston protrusion readings are done in line with piston pin, eliminating rocking movement of piston at any other position of measurement. 1. Check piston protrusion as follows: a. Make sure crankcase deck surface is clean. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

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414

b. Zero dial indicator with magnetic base (page 427) on crankcase deck surface. c.

Position dial indicator tip over piston head at 3 o’clock position.

d. Rotate crankshaft in direction of normal rotation to raise piston to its maximum outward protrusion at cylinder Top Dead Center (TDC). Push down on piston crown before taking reading. Read this maximum protrusion on dial indicator. e. Reposition dial indicator tip on piston head at 9 o’clock position. f.

CAUTION: To prevent engine damage, install connecting rod cap and connecting rod with matching serial numbers on the same side. If the rod cap is reversed or not installed on its matching connecting rod, the fractured mating surfaces will be damaged. A new connecting rod assembly must be installed. Do NOT attempt to reuse a rod that has been misassembled to its cap, assembled with the wrong cap or has been cross-threaded while attempting assembly. Serious engine damage can result. 2. Rotate crankshaft to position journals for removal of connecting rod assemblies. Mark connecting rod locations.

Rotate crankshaft to raise piston to its maximum protrusion. Push down on piston crown before taking reading. Read maximum protrusion on dial indicator.

g. Average the two readings. Replace piston and connecting rod if protrusion is not within specification (page 425).

Piston and Connecting Rod CAUTION: To prevent engine damage, check for a carbon ridge on top of cylinder sleeves. If found, remove carbon ridge with a suitable tool before removing rod and piston assemblies. 1. Scrape carbon ridge from top of cylinder bore, if necessary. Use care not to damage sleeve bore surface. CAUTION: To prevent engine damage, mark with permanent marker or tag each connecting rod and cap with the correct cylinder number. This engine has “cracked” (fractured) type connecting rods. Do not alter or damage fractured mating surfaces of the rod and cap. A cap from one connecting rod is NOT interchangeable with another connecting rod. The matching connecting rod and cap numbers or symbols indicate a matched set.

Figure 565 1. 2.

Connecting rod cap

Connecting rod bolt M12 x 64 (2) Connecting rod cap

CAUTION: To prevent engine damage, assemble connecting rod cap and connecting rod with their fractured mating surfaces in the original orientation. Matching numbers must be next to each other. NOTE: When removed, make sure matching connecting rod and connecting rod cap numbers stay together as a set. A cap from one connecting rod is not interchangeable with any other connecting rod. 3. Using Connecting Rod Bolt Torx® Socket (page 427), remove two connecting rod bolts and connecting rod cap. Save bolts for reuse during connecting rod bore check procedure. CAUTION: To prevent engine damage, do not push on fractured surface of connecting rod.


POWER CYLINDERS CAUTION: To prevent engine damage, do not damage piston cooling jet when removing connecting rod and piston assembly. If jet is bent during piston assembly or removal, replace jet.

415

Piston Disassembly WARNING: To prevent personal injury or death, wear safety glasses with side shields.

4. Remove piston and connecting rod assemblies from cylinder sleeves as follows: a. Rotate engine to a vertical position. b. Use a wooden or plastic handle and push piston and connecting rod assembly from cylinder sleeve. c.

Once piston rings are free of cylinder bore, remove piston and connecting rod assembly from cylinder sleeve.

d. Mark each piston and rod assembly with cylinder number from which each was removed, using a permanent marker.

Figure 567

Piston pin retainer (typical)

1. Using a pair of pliers, remove two piston pin retainers. CAUTION: To prevent engine damage, do not mark piston pin for cylinder and location on outer diameter; place mark only on flat end or tapered inside surface. 2. Remove piston pin from its bore by hand and separate connecting rod from piston.

Figure 566 fit

Correct connecting rod and cap joint

CAUTION: To prevent engine damage, use permanent markers to identify internal engine components and their orientation. Do not use paint or temporary markers. NOTE: Upper connecting rod bearings have an oil hole and lower connecting rod bearings do not. 5. Remove connecting rod upper and lower bearings by pushing out. Mark connecting rod bearings for position and orientation and set aside for inspection.

Figure 568

Piston ring removal (typical)


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416

NOTE: Only expand piston rings enough to fit over top of piston. NOTE: Keep piston rings organized for each cylinder. 3. Using piston ring expansion pliers (page 427), remove top compression ring, taper face compression ring and bevelled oil ring.

CAUTION: To prevent engine damage, use permanent markers to identify internal engine components and their orientation. Do not use paint or temporary markers. NOTE: Care must be taken not to damage piston cooling jets during cylinder sleeve removal. 1. Remove six cylinder sleeves from crankcase as follows:

Cylinder Sleeves

a. Insert Cylinder Sleeve Puller (page 427) into cylinder sleeve. b. Engage removal tool hooks under bottom edge of cylinder sleeve. c.

Position removal tool feet diagonally on crankcase deck surface.

d. Turn threaded shaft clockwise to extract cylinder sleeve. e. Mark cylinder sleeves for position and set aside for inspection. 2. Remove and discard two cylinder sleeve O-rings from each crankcase cylinder sleeve.

Figure 569

Cylinder sleeve removal


POWER CYLINDERS

Cleaning and Inspection Cleaning CAUTION: To prevent engine damage, do not use caustic solvents, wire brushes or bead blasting media to clean aluminum pistons. CAUTION: To prevent engine damage, do not use solvents or a wire brush to clean the fractured mating surface of connecting rods. 1. Use a soap and water solution to clean pistons. Soak piston first and then clean with a non-metallic brush.

2. Check side clearance of taper face compression ring groove as follows: a. Place edge of a new taper face compression ring in its respective ring groove. Roll taper face compression ring all around ring groove to ensure ring is free in its groove. b. With edge of taper face compression ring in taper face compression ring groove, use a feeler gauge (page 427) to measure side clearance between ring and groove. c.

2. Clean piston ring grooves thoroughly. 3. The following disassembled components may be cleaned using a suitable solvent: •

Piston pins

•

Piston pin retainers

4. Thoroughly clean connecting rod bolt holes and threads. Piston Inspection 1. Inspect pistons for scuffed or scored skirts, cracked or worn ring lands and cracked or scuffed pin bores. Replace damaged pistons.

417

Compare taper face compression ring side clearance to specification (page 425). Excessive side clearance indicates ring groove wear and requires piston replacement.

3. Check side clearance of bevelled oil ring groove as follows: a. Place edge of a new bevelled oil ring in its respective ring groove. Roll bevelled oil ring all around ring groove to ensure ring is free in its groove. b. With edge of bevelled oil ring in the bevelled oil ring groove, use a feeler gauge (page 427) to measure side clearance between ring and groove. c.

Compare bevelled oil ring side clearance to specification (page 425). Excessive side clearance indicates ring groove wear and requires piston replacement.

Figure 570 Second and third ring groove clearance check (typical) Figure 571

Piston skirt diameter measurement

NOTE: It is not possible to measure side clearance of top compression ring groove. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

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418

4. Using a 4 - 5 inch micrometer (page 427), measure diameter of piston at intervals given in Specifications (page 425). If measurements do not meet specification, replace piston.

Piston Ring Inspection CAUTION: To prevent engine damage, install new piston rings if a piston is removed. Faulty piston rings cannot always be detected visually. 1. Inspect new piston rings for cleanliness.

Connecting Rod Inspection CAUTION: To prevent engine damage, do not allow fractured mating surfaces of the connecting rod or connecting rod cap to contact any surface other than its matched fractured surface. Contacting any other surface could cause misalignment of the mating surface, resulting in connecting rod bearing and engine failure. CAUTION: To prevent engine damage, do not use solvents or a wire brush to clean the fractured mating surface of connecting rods. 1. Inspect connecting rod bolt threads for nicks or damage. Replace as required. 2. Inspect connecting rod and cap mating surfaces and bearing bore for any indication of damage. Bore must be smooth and free of scoring or nicks. Replace connecting rod if necessary.

Figure 572 Piston ring end gap clearance in cylinder bore

2. Before installing new piston rings, check ring gap for each ring as follows: a. Push piston ring down into cylinder bore. Make sure the piston ring is square with cylinder wall. An inverted piston head can be used to push piston ring to desired location of measurement (usually at top of piston stroke). b. Use a feeler gauge (page 427) to measure ring gap between ends of each piston ring. c.

If gap ring does not meet specification (page 425), select another ring or recheck cylinder sleeve wear.

Figure 573

Inside diameter of piston pin bore

3. Inspect connecting rod piston pin bore for wear as follows: a. Using a telescoping gauge (page 427) and a 2 - 3 inch micrometer (page 427), measure piston pin bore at two locations 90° apart. b. If inside diameter of piston pin bore exceeds specification (page 425), replace connecting rod.


POWER CYLINDERS

419

Connecting Rod Bore Check CAUTION: To prevent engine damage, do not use power tools to remove or install connecting rod cap bolts. Threads will be damaged if a bolt or nut is rotated too quickly. 1. Lightly lubricate USED connecting rod bolts with clean engine oil. Assemble cap to connecting rod without bearings. Tighten bolts to an initial torque of 100 N·m (74 lbf·ft). 2. Rotate each rod bolt 90° clockwise (1/4 turn).

Figure 575

Piston pin measurement

2. Using a 2 - 3 inch micrometer (page 427), measure piston pin outside diameter at two locations 90° apart. Measure each end of pin. If outside diameter of any piston pin is less than minimum specification (page 425), replace piston pin.

Figure 574

Connecting rod bore measurement

3. Using a telescoping gauge (page 427) and a 3 - 4 inch micrometer (page 427), measure connecting rod bearing bore diameter in three locations. If connecting rod bore diameter does not meet specification (page 425), replace connecting rod. 4. After all connecting rod bores are inspected, disassemble connecting rods and discard used connecting rod bolts. 5. With connecting rod cap removed, inspect surface finish of connecting rod bearing bore. Bore must be smooth and free of scoring, nicks or burrs. Replace connecting rod assembly as necessary.

Piston Pin Inspection 1. Inspect piston pins for scoring or wear. Replace as necessary.

Figure 576 Piston pin bore inside diameter measurement (typical) NOTE: These pistons have “profiled” pin bores and must be measured carefully to get an accurate result. NOTE: Measure each piston pin bore inside diameter in front and in rear of piston at one location each, either horizontally (as shown for 13L piston) or vertically (for 11L piston) in the pin bore the specified distance from the center line of the piston.


POWER CYLINDERS

420

3. Using a telescoping gauge (page 427) and 2 3 inch micrometer (page 427), measure each piston pin bore inside diameter at one location either vertically (11L piston) or horizontally (13L piston) the specified distance from center of piston. If piston pin bore inside diameter is not within specification (page 425), replace piston. 4. To check piston pin running clearance, subtract outside diameter of piston pin from inside diameter of piston pin bore. If clearance exceeds specification (page 425), replace piston pin and check piston pin clearance using new piston pin.

Cylinder Sleeve Inspection 1. Install six cylinder sleeves (without cylinder sleeve O-rings) into crankcase.

Figure 578 Cylinder sleeve protrusion measurement 1. 2.

Dial indicator with magnetic base Sleeve Protrusion Hold Down Clamp

3. Check cylinder sleeve crankcase deck as follows:

protrusion

above

a. Install Sleeve Protrusion Hold Down Clamps (page 427) using four included bolts. Torque bolts to special torque (page 426). b. Place dial indicator with magnetic base (page 427) on crankcase deck surface. c.

Figure 577

Cylinder sleeve bore measurement

2. Using a dial bore gauge (page 427), measure the cylinder sleeve inside diameter at 120° intervals, at four different depths of cylinder sleeve. If cylinder sleeve inside diameter is not within specification (page 425), replace cylinder sleeve.

Position dial indicator tip on crankcase deck adjacent to cylinder sleeve flange. Zero dial indicator.

d. Carefully pivot dial indicator until tip is resting on cylinder sleeve flange. Record reading. e. Measure cylinder sleeve protrusion at three locations evenly spaced around the cylinder sleeve. f.

If any of the three readings of cylinder sleeve protrusion are not within specification (page 425), fit new cylinder sleeve and repeat steps a through e.

g. If after trying all available new cylinder sleeves and specification still cannot be met, contact Tech Central at 1-800-336-4500. h. Remove six cylinder sleeves and continue with installation.


POWER CYLINDERS

Installation Cylinder Sleeves 1. Lubricate two new cylinder sleeve O-rings with clean engine oil and install in crankcase cylinder sleeve bore. 2. Using a soft-faced hammer, install cylinder sleeve by striking evenly until seated.

421

b. Install oil scraper component of bevelled oil ring over expansion spring with the gap 180° from the spring wire latch. c.

Install taper face compression ring into middle piston groove. Make sure ring is installed with identification mark facing up.

d. Install top compression ring into top piston groove. Make sure ring is installed with identification mark facing up.

Piston Assembly

2. Space ring gaps approximately 120° apart after ring installation.


3. Connect piston to connecting rod as follows: a. Lubricate connecting rod piston pin bore, piston pin bore and piston pin with clean engine oil. b. Set piston crown down so arrow mark stamped on piston crown is at 6 o’clock position. c.

Using pliers, install one piston pin retainer into groove. Be sure that retainer is fully seated in groove and that tang ends point up.

d. Hold connecting rod so open end faces 3 o’clock position of piston when installed. e. Place connecting rod into piston.

Figure 579

Piston ring installation (typical)

CAUTION: To prevent engine damage, install piston rings correctly. Both top compression and taper face compression rings have the same identification markings. The marking must face up for the ring to be installed correctly. The taper face compression ring has a rectangular cross section and goes in the middle groove. The top compression ring has a keystone cross section and goes in the top groove. NOTE: Only expand piston rings enough to fit over top of piston. 1. Using piston ring expansion pliers (page 427), install piston rings. Be careful not to “wind” ring into groove. a. Install expansion spring component of bevelled oil ring into bottom piston groove.

Figure 580

f.

Piston pin retainer

Slide piston pin through piston holes, stopping at installed piston pin retainer.

g. Using pliers, install second piston pin retainer.


POWER CYLINDERS

422 Piston and Connecting Rod

1. Turn crankshaft so crank pin (connecting rod journal) on the cylinder to receive piston installation is at the bottom of its stroke. 2. Lightly coat piston and piston rings with clean engine oil. 3. Coat cylinder sleeve walls, crankshaft journals and Piston Ring Compressor (page 427) with clean engine oil. 4. Place piston in Piston Ring Compressor (page 427). NOTE: Upper connecting rod bearings have an oil hole and lower connecting rod bearings do not. 5. Install connecting rod bearings in connecting rod and cap. Bearings with oil hole go in the upper position. Coat bearings with clean engine oil. Be sure that all bearing locator tabs and oil holes are in alignment with connecting rod and cap and that bearings are flush to fractured mating faces of rod and cap.

Figure 581

Arrow mark on piston (typical)

CAUTION: To prevent engine damage, the arrow stamped on top of piston must face front of engine. CAUTION: To prevent engine damage, do not damage piston cooling jet when installing connecting rod and piston assembly. If jet is bent during piston assembly installation, replace jet. CAUTION: To prevent engine damage, do not allow fractured mating surfaces of the connecting rod or connecting rod cap to contact any surface other than its matched fractured surface. Contacting any other surface could cause misalignment of the mating surface, resulting in connecting rod bearing and engine failure. NOTE: Before installing piston and connecting rod assembly, make sure all piston cooling jets are installed. 6. Carefully put piston and piston ring compressor combination and connecting rod assembly in cylinder sleeve with arrow mark facing towards front of engine.

Figure 582 Piston and connecting rod assembly installation (typical) 7. Once piston and connecting rod assembly has been inserted in cylinder sleeve, use a handle (wood or plastic) of a hammer to tap piston into cylinder sleeve. Guide connecting rod in place on crankshaft. Do not let edges of connecting rod or fractured mating face of rod touch the crankshaft journal. Before installing cap with bearing and starting bolts, be sure that bearings are still flush with connecting rod and cap fractured mating faces and have NOT rotated.


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423

CAUTION: To prevent engine damage, lightly lubricate bolt threads and mating surfaces of bolt flanges with clean engine oil. Too much oil causes hydrostatic lock and gives incorrect torque reading. 8. Lightly apply clean engine oil to new bolt threads for connecting rod and upper and lower bearings in cap before installing bolts.

Figure 584 1. 2.

Connecting rod cap

Connecting rod bolt (2) Connecting rod cap

CAUTION: To prevent engine damage, install new connecting rod bolts. Figure 583 fit

Correct connecting rod and cap joint

CAUTION: To prevent engine damage, install connecting rods with correct caps in the correct direction. If a rod cap is reversed, an offset will be seen at the mating surfaces. If a reverse assembly is installed on the crankshaft, the connecting rod must be replaced. Also, check crank pin (connecting rod journal) fillets for damage that would require replacement of the crankshaft. 9. Assemble cap to connecting rod with matching identification code on same crankshaft journal from which it was removed. Be certain that longer leg of connecting rod is positioned towards left side of crankcase.

CAUTION: To prevent engine damage, do not use powered tools to install connecting rod bolts; rotating bolts too quickly can damage threads. CAUTION: To prevent engine damage, do not rotate crankshaft until connecting rod bolts are fully tightened, as this may cause bearings to rotate in place. 10. Install two NEW connecting rod bolts. 11. Using Connecting Rod Bolt Torx® Socket (page 427), tighten connecting rod bolts evenly to an initial torque of 100 N·m (74 lbf·ft). 12. Rotate (tighten) connecting rod bolts an additional 90 degrees (1/4 turn). 13. Repeat installation procedure for remaining piston and connecting rod assemblies.


POWER CYLINDERS

424 Engine Run-in Procedure

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. Use the following engine run-in procedure after installing new pistons, piston rings, piston pins or cylinder sleeves: 1. Start engine and run at low idle with no load. If engine does not exceed 138 kPa (20 psi) oil pressure within 20 to 30 seconds, shutdown engine and correct the problem. 2. Run engine at low idle with no load for 5 minutes and check for any of the following problems: •

Unusual noise

•

Coolant leaks

•

Oil leaks

•

Fuel leaks

•

Air leaks

•

Excessive exhaust smoke

•

Excessive vibration

•

Loose turbocharger mounting

3. Turn engine off and correct any of these problems to prevent engine or turbocharger damage. 4. Wait 15 minutes for oil level to stabilize, then check engine oil level. Add oil if needed. See appropriate Engine Operation and Maintenance Manual for correct grade and viscosity of engine oil. 5. Start engine and drive vehicle (unloaded) for 30 minutes in city mode, then drive vehicle (unloaded) for an additional 60 minutes in highway mode. Verify no loss in power. 6. Return to idle and check for leaks. 7. Turn off engine and repair any leaks.


POWER CYLINDERS

425


Power Cylinders

Connecting Rods Piston pin bore inside diameter Connecting rod bearing bore diameter (crankshaft end)

52.06 ± 0.005 mm (2.0496 ± 0.0001 in)

95.000 to 95.022 mm (3.7402 to 3.7402 in)

Pistons — 11L Skirt diameter measured 16 mm from piston bottom edge, 90° to piston pin axis in “window” on skirt graphite layer, where applicable Piston protrusion measured from crankcase deck to piston Piston pin bore inside diameter, measured vertically, 38 mm from piston center Piston pin running clearance

119.88 ± 0.009 mm (4.7197 ± 0.0004 in)

0.3 ± 0.22 mm (0.0118 ± 0.009 in)

52.010 - 52.016 mm (2.0476 - 2.0479 in) 0.010 - 0.024 mm (0.0004 - 0.0009 in)

Pistons — 13L Skirt diameter measured 26.9 mm from piston bottom edge, 90° to piston pin axis in “window” on skirt graphite layer, where applicable Piston protrusion measured from crankcase deck to piston

125.950 ± 0.013 mm (4.9587 ± 0.0005 in)

0.3 ± 0.22 mm (0.0118 ± 0.009 in)

Piston pin bore inside diameter, measured horizontally 26 mm from piston center

52.04 - 52.05 mm (2.0490 - 2.0492 in)

Piston pin running clearance

0.040 - 0.058 mm (0.0016 - 0.0023 in)

Piston Pins Outside diameter

51.992 - 52.000 mm (2.0469 - 2.0472 in)

Piston Rings — 11L Top compression ring Ring gap

0.4 - 0.55 mm (0.0157 - 0.0217 in)

Taper face compression ring Ring gap

1.00 - 1.20 mm (0.0393 - 0.0472 in)

Side clearance

0.09 - 0.13 mm (0.0035 - 0.0051 in)

Bevelled oil ring


POWER CYLINDERS

426

Table 40

Power Cylinders (cont.)

Ring gap

0.25 - 0.50 mm (0.0098 - 0.0197 in)

Side clearance

0.03 - 0.07 mm (0.0012 - 0.0028 in)


0.4 - 0.55 mm (0.0157 - 0.0217 in)


1.00 - 1.20 mm (0.0394 - 0.0472 in)

Side clearance

0.09 - 0.13 mm (0.0035 - 0.0051 in)

Bevelled oil ring Ring gap

0.25 - 0.50 mm (0.0098 - 0.0197 in)

Side clearance

0.05 - 0.09 mm (0.0020 - 0.0035 in)

Cylinder sleeve dimensions — 11L Sleeve protrusion Sleeve inside diameter (bore)

0.050 - 0.085 mm (0.0019 - 0.0033 in) 120 ± 0.01 mm (4.7244 ± 0.0004 in)


0.050 - 0.085 mm (0.0019 - 0.0033 in) 126 ± 0.01 mm (4.9606 ± 0.0004 in)


Power Cylinders

Connecting rod bolts Sleeve Protrusion Hold Down Clamp bolts



POWER CYLINDERS

427


Power Cylinders

Description

Tool Number


Obtain locally


Obtain locally


Obtain locally

Connecting Rod Bolt Torx® Socket

ZTSE4843

Cylinder Sleeve Puller

ZTSE2536

Dial bore gauge

Obtain locally


Obtain locally

Feeler gauge

Obtain locally

Piston ring compressor

Obtain locally

Piston ring expansion pliers

Obtain locally

Sleeve Protrusion Hold Down Clamps Telescoping gauge



428

POWER CYLINDERS


CRANKCASE AND CRANKSHAFT

429

Table of Contents

Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .432 Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433 Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433 Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434 Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435 Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435 Crankshaft Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435 Main Bearings Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436 Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438 Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438 Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441


430




431

Exploded View

Figure 585 1. 2. 3. 4.

Crankcase and crankshaft

M18 x 2 x 160.5 collar bolt (14) Lower main bearing (7) Crankshaft Upper main bearing (with oil hole) (7)

5. 6. 7. 8.

M6 x 12 bolt (6) Crankcase Piston cooling jet (6) Upper thrust washer (main bearing) (2)

9.

Lower thrust washer (main bearing) (2)



432

Removal


Engine Electrical

•


•

Cold Start Assist

•


•


•

Turbochargers

•


•

Fuel System


•


•



•


•


•

MaxxForce® equipped)

•


•


•

Oil Pan and Oil Pickup Tube

•


•

Power Cylinders


WARNING: To prevent personal injury or death, make sure the engine has cooled before removing components. WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.


Engine

Brake

by


Jacobs

(if

CRANKCASE AND CRANKSHAFT Preliminary Checks

Figure 586

Crankshaft end play

1. Check crankshaft end play as follows: a. Mount dial indicator with magnetic base (page 441) on crankcase with indicator tip on end of crankshaft as shown. b. Move crankshaft forward with pry bar and zero the dial indicator. c.

Move crankshaft back and forth while reading dial indicator. Compare dial indicator reading with specification (page 441).

d. If end play exceeds specified limits, replace main bearing thrust washers. Crankshaft 1. Position engine so that bottom of main bearing caps are facing upwards. CAUTION: To prevent engine damage, use permanent markers to identify internal components or their orientation. Do not use paint or temporary markers.

433

2. Mark main bearing caps for location and orientation.

Figure 587 1. 2.

Main bearing caps

M18 x 160.5 collar bolt (14) Main bearing cap (7)

CAUTION: To prevent engine damage, do not drop main bearing caps. Damage to the fractured mating surface of a main bearing cap will require replacement of the crankcase and mated main bearing caps. 3. Remove 14 M18 x 160.5 collar bolts and seven main bearing caps. Save bolts for Main Bearing measurement procedure (page 436). 4. Remove seven lower main bearings and two lower thrust washers from main bearing caps by pushing out. CAUTION: To prevent engine damage, use permanent markers to identify internal components or their orientation. Do not use paint or temporary markers. 5. Number removed lower main bearings and lower thrust washers on back side (not running surface) and set aside for inspection.


434


8. Number removed upper main bearings and upper thrust washers on back side (not running surface) to match the previously removed lower main bearings and lower thrust washers and set aside for inspection.

Piston Cooling Jets

Figure 588

Crankshaft removal

WARNING: To prevent personal injury or death, use a correct size lifting sling and hoist with a safety latch on hook. CAUTION: To prevent engine damage, do not bend, drop or damage crankshaft. NOTE: Use only a soft-sided lifting sling. Do not use chains or steel cables. 6. Attach lifting sling (page 441) to crankshaft. Lift crankshaft up and out of crankcase and set aside for inspection.

Figure 589 1. 2.

Piston cooling jet

M6 x 12 bolt (6) Piston cooling jet (6)

Remove six M6 x 12 bolts and six piston cooling jets.

7. Remove upper main bearings and upper thrust washers from crankcase by pushing out.



Cleaning, Inspection and Testing Crankcase WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi). CAUTION: To prevent engine damage, do not use chlorinated solvents on bolts or crankcase tapped holes. Parts should be clean, dry and free of any chemicals other than engine oil. NOTE: Thoroughly clean and inspect crankcase before and after reconditioning. 1. Clean crankcase in a chemical bath or hot tank. This removes all carbonized material and mineral deposits in coolant passages. CAUTION: To prevent engine damage, do not use a wire brush to clean the fractured mating surface of crankcase and main bearing caps.

435

CAUTION: To prevent engine damage, clean and dry threads in the crankcase bolt holes with filtered compressed air. Dirt or oil in holes may cause binding and incorrect torque readings. 3. Clean cylinder head bolt holes with Head Bolt Bottoming Tap (page 441). 4. Clean collar bolt holes with Main Bolt Bottoming Tap (page 441). 5. Clean out debris with filtered compressed air.

Crankshaft Measurement 1. Clean and inspect crankshaft and main bearings. 2. Clean crankshaft with a suitable solvent. 3. Use a stiff nylon brush to clean oil passages in crankshaft. Loosen accumulated dirt, sludge and deposits. 4. Flush oil passages with a suitable solvent.

2. If a hot tank is not available, do the following steps: a. Use non-metallic stiff bristle brushes and scrapers to clean gasket material from machined surfaces of crankcase.


b. Clean crankcase in solvent.

5. Dry with filtered compressed air.

c.

6. Inspect crankshaft journals (main and connecting rod) for scratches, grooves and scoring.

Dry with filtered compressed air.

Figure 590

Cylinder head bolt holes Figure 591 Crankshaft main bearing journal measurement



436

1. Inspect each main bearing for scratches, grooves, scoring, pitting and wear. Replace bearings as required. 2. Using a flat surface, place an individual bearing half on the surface as shown. 3. Using a 4 - 5 inch micrometer (page 441), measure across the ends of the bearing half as shown.

Figure 592 Crankshaft connecting rod bearing journal measurement CAUTION: To prevent engine damage, do not rework bearings or bearing caps to reduce journal-to-bearing running clearances. Grind or install new crankshaft. 7. Use a 3 - 4 inch micrometer (page 441) to measure diameter of each connecting rod journal, and a 4 - 5 inch micrometer (page 441) to measure diameter of each main journal. Measure each journal at both sides next to fillet radius at two directions 90° apart. Move micrometer over entire width of journal. If journal wear exceeds specification (page 441), have crankshaft machined, or replace crankshaft. Main Bearings Measurement

4. If the measurement falls outside of the uninstalled bearing outside diameter (free spread) specification (page 441), replace upper and lower bearing halves as a set. Measure all upper and lower bearing halves and replace bearings as required. 5. Install upper main bearings into crankcase and lower main bearings into main bearing caps in their original positions and orientation. CAUTION: To prevent engine damage, install main bearing caps with their fractured mating surfaces in the original orientation. 6. Lightly coat used collar bolt threads and under bolt heads with clean engine oil. Do not use new bolts for this inspection procedure. 7. With crankshaft still removed, install seven main bearing caps and 14 previously removed M18 x 160.5 collar bolts. 8. Tighten M18 x 160.5 collar bolts in main bearings caps as follows: a. Tighten collar bolts at No. 6 main bearing cap to 10 N·m (88 lbf·in). b. Tighten remaining collar bolts to 10 N·m (88 lbf·in). c.

Tighten collar bolts at No. 6 main bearing cap to 100 N·m (74 lbf·ft).

d. Tighten remaining collar bolts to 100 N·m (74 lbf·ft). e. Tighten collar bolts at No. 6 main bearing cap to 300 N·m (221 lbf·ft). f. Figure 593 Main bearing uninstalled outside diameter (free spread) measurement

Tighten remaining collar bolts to 300 N·m (221 lbf·ft).

g. Turn collar No. 6 main bearing cap an additional 90° clockwise.



h. Turn remaining collar bolts an additional 90° clockwise.

437

measurement does not meet specification (page 441), replace main bearings. 10. Remove 14 M18 x 160.5 collar bolts, seven main bearing caps, upper main bearings and lower main bearings. Discard used collar bolts.

Piston Cooling Jets 1. Hold each piston cooling jet under running water. Water should stream from jet end. WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit compressed air pressure to 207 kPa (30 psi).

Figure 594 Main bearing installed diameter measurement

2. Clear blocked piston cooling jets using filtered compressed air. Replace piston cooling jet if blockage cannot be cleared. 3. Replace any cracked or bent jets.

9. Using a dial bore gauge (page 441), measure main bearing installed inside diameter. If



438

Installation Piston Cooling Jets

Figure 596

Figure 595 1. 2.

Piston cooling jet

M6 x 12 bolt (6) Piston cooling jet (6)

1. Install six piston cooling jets and six M6 x 12 bolts. 2. Tighten bolts to special torque (page 441).

Main bearing

NOTE: When inserting main bearings, make sure oil is not between back side of bearing and crankcase bearing saddles. 2. Place upper main bearings in crankcase. Make sure locking tabs on bearings are snapped into saddle and oil holes in bearings line up with oil holes in crankcase. 3. Lubricate running surface of bearings with clean engine oil.

Crankshaft NOTE: Make sure crankshaft and bearings have been inspected per instructions in this section before proceeding. 1. Use a lint-free cloth to wipe crankcase bearing saddles free of oil.

Figure 597

Crankshaft installation

WARNING: To prevent personal injury or death, use a correct size lifting sling and hoist with a safety latch on hook. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved


439

CAUTION: To prevent engine damage, do not bend, drop or damage crankshaft.

locking tabs align with notches in main bearing cap.

NOTE: Use only a soft-sided lifting sling. Do not use chains or steel cables.

7. Place lower main bearings in main bearing caps. Make sure locking tabs on bearings are snapped into main bearing caps.

4. Attach lifting sling (page 441) to crankshaft. Orient crankshaft with front flange (8 bolt holes) and rear flange (10 bolt holes) at crankcase front and rear, respectively. Carefully lower crankshaft down into crankcase.

8. Lubricate bearings with clean engine oil.

Figure 599 Figure 598

Thrust washer installation

NOTE: Make sure oil grooves on thrust washers face outward towards crankshaft thrust surface. 5. Install two upper thrust washers into crankcase at No. 6 main location as follows: a. Set upper thrust washer on top of crankshaft at No. 6 main journal with grooves towards crankshaft thrust surface. b. Pivot upper thrust washer around crankshaft and down into position.

1. 2.

Main bearing caps

Collar M18 x 160.5 bolt (14) Main bearing cap (7)

CAUTION: To prevent engine damage, install main bearing caps with their fractured mating surfaces in the original orientation. CAUTION: To prevent engine damage, do not drop main bearing caps. Damage to the fractured mating surface of a main bearing cap will require replacement of the crankcase and mated main bearing caps. 9. Install seven main bearing caps and 14 new M18 x 160.5 collar bolts.

6. Install two lower thrust washers onto No. 6 main bearing cap. Make sure lower thrust washer


440


10. Tighten collar bolts as follows: a. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 10 N·m (88 lbf·in). b. Tighten remaining collar bolts to 10 N·m (88 lbf·in). c.

Rotate crankshaft to verify that crankshaft does not bind. Correct as required.

d. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 100 N·m (74 lbf·ft).

e. Tighten remaining collar bolts to 100 N·m (74 lbf·ft). f.

Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 300 N·m (221 lbf·ft).

g. Tighten remaining collar bolts to 300 N·m (221 lbf·ft). h. Turn two collar bolts at No. 6 (thrust washer location) main bearing cap bolts an additional 90°. i.

Turn remaining collar bolts an additional 90°.



441


Crankcase and Crankshaft

Crankshaft Main Bearing: Journal diameter Installed bearing inside diameter Uninstalled bearing outside diameter (free spread)

103.98 - 104.00 mm (4.0937 - 4.0945 in) 104.044 - 104.09 mm (4.0962 - 4.0980 in) 111.20 - 112.40 mm (4.3779 - 4.4252 in)

Connecting Rod Bearing: Journal diameter

89.98 - 90.00 mm (3.5425 - 3.5433 in)

Crankshaft end play: Maximum service

0.200 - 0.401 mm (0.0079 - 0.0158 in)



Collar bolts (main bearing cap), M18 x 160.5 Piston cooling jet bolts, M6 x 12

See tightening procedure and sequence 13 N·m (115 lbf·in)



Description

Tool Number


Obtain locally


Obtain locally

Dial bore gauge

Obtain locally


Obtain locally

Head Bolt Bottoming Tap Lifting sling


Main Bolt Bottoming Tap


ZTSE4854

442



ABBREVIATIONS AND ACRONYMS

443

Table of Contents

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445 Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445


444




Abbreviations and Acronyms Abbreviations and Acronyms A or amp – Ampere AAT – Ambient Air Temperature ABDC – After Bottom Dead Center ABS – Antilock Brake System AC – Alternating Current A/C – Air Conditioner ACC – Air Conditioner Control ACCEL – Accelerate ACD – Air Conditioner Demand ACM – Aftertreatment Control Module ACT PWR GND – Actuator Power Ground ACV – Air Control Valve AF – Air to Fuel ratio AFT – Aftertreatment AFTFD – Aftertreatment Fuel Doser AFTFDH – Aftertreatment Fuel Doser High AFTFDL – Aftertreatment Fuel Doser Low AFTFIT – Aftertreatment Fuel Inlet Temperature AFTFIS – Aftertreatment Fuel Inlet Sensor AFTFP – Aftertreatment Fuel Pressure AFTFP1 – Aftertreatment Fuel Pressure 1 AFTFP2 – Aftertreatment Fuel Pressure 2 AFTFSH – Aftertreatment Fuel Shutoff High AFTFSL – Aftertreatment Fuel Shutoff Low AFTFSV – Aftertreatment Fuel Shutoff Valve AIT – Air Inlet Temperature Amb – Ambient amp or A – Ampere AMS – Air Management System API – American Petroleum Institute APP – Accelerator Pedal Position APP1 – Accelerator Pedal Position 1 APP2 – Accelerator Pedal Position 2 ASTM – American Society for Testing and Materials ATA – American Trucking Association ATAH – American Trucking Association Link High ATAL – American Trucking Association Link Low ATDC – After Top Dead Center AWG – American Wire Gauge B+ or VBAT – Battery Voltage BARO – Barometric Absolute Pressure BBDC – Before Bottom Dead Center BDC – Bottom Dead Center bhp – Brake Horsepower BOO – Brake On / Off BPP – Brake Pedal Position BPS – Brake Pressure Switch BTDC – Before Top Dead Center

445

BTU – British Thermal Unit C – Celsius CAC – Charge Air Cooler CACOT – Charge Air Cooler Outlet Temperature CAN – Controller Area Network CAP – Cold Ambient Protection CARB – California Air Resources Board cc – Cubic centimeter CCA – Cold Cranking Ampere CCOSS – Crankcase Oil Separator Speed cfm – Cubic feet per minute cfs – Cubic feet per second CFV – Coolant Flow Valve CID – Cubic Inch Displacement CKP – Crankshaft Position CKPH – Crankshaft Position High CKPL – Crankshaft Position Low CKPO – Crankshaft Position Out cm – Centimeter CMP – Camshaft Position CMPH – Camshaft Position High CMPL – Camshaft Position Low CMPO – Camshaft Position Out CMV – Coolant Mixer Valve CO – Carbon Monoxide COO – Cruise On / Off switch CPU – Central Processing Unit CSFI – Cold Start Fuel Igniter CSFS – Cold Start Fuel Solenoid CSR – Cold Start Relay CTC – Coolant Temperature Compensation Cyl – Cylinder DB – Decibel DCA – Diesel Coolant Additive DDI – Digital Direct Fuel Injection DDS – Driveline Disengagement Switch DLC – Data Link Connector DME – Dimethyl Ether DMM – Digital Multi-meter DOC – Diesel Oxidation Catalyst DOCIT – Diesel Oxidation Catalyst Inlet Temperature DOCOT – Diesel Oxidation Catalyst Outlet Temperature DPF – Diesel Particulate Filter DPFDP – Diesel Particulate Filter Differential Pressure DPFIT – Diesel Particulate Filter Inlet Temperature DPFOT – Diesel Particulate Filter Outlet Temperature DSI – Down Stream Injection DT – Diesel Turbocharged DTC – Diagnostic Trouble Code


446


DTRM – Diesel Thermo Recirculation Module EBP – Exhaust Back Pressure EBPD – Exhaust Back Pressure Desired EBPV – Exhaust Back Pressure Valve ECB – Engine Compression Brake ECB1 – Engine Compression Brake 1 ECB2 – Engine Compression Brake 2 ECBP – Engine Compression Brake Pressure ECI – Engine Crank Inhibit ECL – Engine Coolant Level ECM – Engine Control Module ECM GND – Engine Control Module Ground ECM PWR – Engine Control Module Power ECS – Engine Coolant System ECSR – Engine Controlled Shutdown Request ECT – Engine Coolant Temperature ECT1 – Engine Coolant Temperature 1 ECT2 – Engine Coolant Temperature 2 EFAN – Engine Fan EFC – Engine Fan Control EFRC – Engine Family Rating Code EFS – Engine Fan Speed EFT – Engine Fuel Temperature EG – Ethylene Glycol EGC – Electronic Gauge Cluster EGBP – Exhaust Gas Back Pressure EGDP – Exhaust Gas Differential Pressure EGR – Exhaust Gas Recirculation EGRC – Exhaust Gas Recirculation Control EGRH – Exhaust Gas Recirculation High control EGRL – Exhaust Gas Recirculation Low control EGROT – Exhaust Gas Recirculation Outlet Temperature EGRP – Exhaust Gas Recirculation Position EGRT – Exhaust Gas Recirculation Temperature EGT – Exhaust Gas Temperature EGT1 – Exhaust Gas Temperature 1 EGT2 – Exhaust Gas Temperature 2 EGT3 – Exhaust Gas Temperature 3 EMI – Electromagnetic Interference EMP – Exhaust Manifold Pressure EMT – Exhaust Manifold Temperature EOL – Engine Oil Level EOP – Engine Oil Pressure EOT – Engine Oil Temperature EPA – Environmental Protection Agency EPR – Engine Pressure Regulator ESC – Electronic System Controller ESN – Engine Serial Number EST – Electronic Service Tool ETC – Engine Throttle Control

ETCH – Engine Throttle Control High ETCL – Engine Throttle Control Low ETP – Engine Throttle Position ETV – Engine Throttle Valve EWPS – Engine Warning Protection System F – Fahrenheit FCV – Fuel Coolant Valve FDP – Fuel Delivery Pressure FEL – Family Emissions Limit fhp – Friction horsepower FMI – Failure Mode Indicator FPC – Fuel Pump Control FPCV – Fuel Pressure Control Valve fpm – Feet per minute FPM – Fuel Pump Monitor fps – Feet per second FRP – Fuel Rail Pressure ft – Feet FVCV – Fuel Volume Control Valve GND – Ground (electrical) gal – Gallon gal/h – U.S. Gallons per hour gal/min – U.S. Gallons per minute GCW – Gross Combined Weight GCWR – Gross Combined Weight Rating GPC – Glow Plug Control GPD – Glow Plug Diagnostic GPR – Glow Plug Relay GVW – Gross Vehicle Weight H2O – Water HC – Hydrocarbons HEST – High Exhaust System Temperature HFCM – Horizontal Fuel Conditioning Module Hg – Mercury hp – Horsepower HPCAC – High-Pressure Charge Air Cooler HPCR – High-Pressure Common Rail HPFP – High-Pressure Fuel Pump hr – Hour HS – Humidity Sensor Hyd – Hydraulic IAH – Inlet Air Heater IAHC – Inlet Air Heater Control IAHD – Inlet Air Heater Diagnostic IAHR – Inlet Air heater Relay IC – Integrated Circuit ICP – Injection Control Pressure ICPR – Injection Control Pressure Regulator ICG1 – Injector Control Group 1 ICG2 – Injector Control Group 2 ID – Inside Diameter


ABBREVIATIONS AND ACRONYMS IGN – Ignition ILO – Injector Leak Off IMP – Intake Manifold Pressure IMT – Intake Manifold Temperature in – Inch inHg – Inch of mercury inH2O – Inch of water INJs – Injectors IPR – Injection Pressure Regulator IPR PWR – Injection Pressure Regulator Power ISC – Interstage Cooler ISIS – International® Service Information System IST – Idle Shutdown Timer ITP – Internal Transfer Pump J1939H – J1939 Data Link High J1939L – J1939 Data Link Low JCT – Junction (electrical) kg – Kilogram km – Kilometer km/h – Kilometers per hour km/l – Kilometers per liter KOEO – Key-On Engine-Off KOER – Key-On Engine-Running kPa – Kilopascal L – Liter L/h – Liters per hour L/m – Liters per minute L/s – Liters per second lb – Pound lbf – Pounds of force lb/s – Pounds per second lbf ft – Pounds of force per foot lbf in – Pounds of force per inch lbm – Pounds of mass LSD – Low Sulfur Diesel m – Meter m/s – Meters per second MAF – Mass Air Flow MAF GND – Mass Air Flow Ground MAG – Magnetic MAP – Manifold Absolute Pressure MAT – Manifold Air Temperature mep – Mean effective pressure mi – Mile MIL – Malfunction Indicator Lamp mm – Millimeter mpg – Miles per gallon mph – Miles per hour MPR – Main Power Relay MSDS – Material Safety Data Sheet MSG – Micro Strain Gauge

447

MSM – Multiplex System Module MY – Model Year NC – Normally closed (electrical) NETS – Navistar Electronics Technical Support Nm – Newton meter NO – Normally Open (electrical) NOX – Nitrogen Oxides O2S – Oxygen Sensor O2SH – Oxygen Sensor Heater OAT – Organic Acid Technology OCC – Output Circuit Check OCP – Overcrank Protection OD – Outside Diameter OL – Over Limit ORH – Out-of-Range High ORL – Out-of-Range Low OSHA – Occupational Safety and Health Administration OWL – Oil/Water Lamp PID – Parameter Identifier P/N – Part Number PDOC – Pre-Diesel Oxidation Catalyst ppm – Parts per million PROM – Programmable Read Only Memory psi – Pounds per square inch psia – Pounds per square inch absolute psig – Pounds per square inch gauge pt – Pint PTO – Power Takeoff PWM – Pulse Width Modulate PWR – Power (voltage) qt – Quart RAM – Random Access Memory RAPP – Remote Accelerator Pedal Position RAS – Resume / Accelerate Switch (speed control) REPTO – Rear Engine Power Takeoff RFI – Radio Frequency Interference rev – Revolution rpm – Revolutions per minute RPRE – Remote Preset Power Take Off RSE – Radiator Shutter Enable RVAR – Remote Variable SAE – Society of Automotive Engineers® SCA – Supplemental Cooling Additive SCCS – Speed Control Command Switches SCS – Speed Control Switch SHD – Shield (electrical) SID – Subsystem Identifier SIG GND – Signal Ground SIG GNDB – Signal Ground Body SIG GNDC – Signal Ground Chassis


448


SIG GNDE – Signal Ground Engine S/N – Serial Number SPEEDO – Speedometer SPN – Suspect Parameter Number SW – Switch (electrical) SWBAT – Switch Battery SYNC – Synchronization TACH – Tachometer output signal TBD – To Be Determined TC2CIS – Turbocharger 2 Compressor Inlet Sensor TC1TOP – Turbocharger 1 Turbine Outlet Pressure TC2TOP – Turbocharger 2 Turbine Outlet Pressure TC1WC – Turbocharger 1 Wastegate Control TC2WC – Turbocharger 2 Wastegate Control TCAPE – Truck Computer Analysis of Performance and Economy TCM – Transmission Control Module TDC – Top Dead Center TDE – Transmission Driving Engaged TOP – Transmission Oil Pressure TOSS – Transmission Output Shaft Speed TOT – Transmission Oil Temperature TTS – Transmission Tailshaft Speed ULSD – Ultra Low Sulfur Diesel UVC – Under Valve Cover

V – Volt VBAT or B+ – Battery Voltage VC – Volume Control VEPS – Vehicle Electronics Programming System VIGN – Ignition Voltage VIN – Vehicle Identification Number VOP – Valve Opening Pressure VRE – Vehicle Retarder Enable VREF – Reference Voltage VREFB – Reference Voltage Body VREFC – Reference Voltage Chassis VREFE – Reference Voltage Engine VSO – Vehicle Speed Output VSS – Vehicle Speed Sensor VSSH – Vehicle Speed Sensor High VSSL – Vehicle Speed Sensor Low WTSL – Wait to Start Lamp WEL – Warn Engine Lamp WIF – Water In Fuel WIFL – Water In Fuel Lamp WTEC – World Transmission Electronically Controlled automatic transmissions (Allison) XCS – Transfercase XMSN – Transmission


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Table of Contents

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451 Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451


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Terminology Terms Accelerator Pedal Position (APP) sensor – A potentiometer sensor that indicates the position of the throttle pedal. Accessory work – The work per cycle required to drive engine accessories (normally, only those essential to engine operation). Actuator – A device that performs work in response to an input signal. Actuator Control – The ECM controls the actuators by applying a low-level signal (low-side driver) or a high-level signal (high side driver). When switched on, both drivers complete a ground or power circuit to an actuator.

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Air entering the radiator may or may not be the same ambient due to possible heating from other sources or recirculation. (SAE J1004 SEP81) Ampere (amp) – The standard unit for measuring the strength of an electrical current. The flow rate of a charge in a conductor or conducting medium of one coulomb per second. (SAE J1213 NOV82) Analog – A continuously variable voltage. Analog to digital converter (A/D) – A device in the ECM that converts an analog signal to a digital signal. American Trucking Association (ATA) Datalink – A serial datalink specified by the American Trucking Association and the SAE. Boost pressure – 1. The pressure of the charge air leaving the turbocharger.

Aeration – The entrainment of air or combustion gas in coolant, lubricant, or fuel.

2. Inlet manifold pressure that is greater than atmospheric pressure. Obtained by turbocharging.

Aftercooler (Charge Air Cooler) – A heat exchanger mounted in the charge air path between the turbocharger and engine intake manifold. The aftercooler reduces the charge air temperature by transferring heat from the charge air to a cooling medium (usually air).

Bottom Dead Center (BDC) – The lowest position of the piston during the stroke.

Aftertreatment Fuel Doser (AFTFD) – A part of the Downstream Injection (DSI) unit that sends pressurized fuel to the Aftertreatment Fuel Injector (AFI) to inject fuel into the exhaust pipe. Aftertreatment (AFT) system – A part of the exhaust system that processes engine exhaust to meet emission requirements and traps particulate matter (soot) to prevent it from leaving the tailpipe. Air Control Valve (ACV) – Contains the LP turbocharger wastegate control port, HP turbocharger wastegate control port, the EBPV control port, and the TC1TOP port. Although these components are integral to the ACV, each circuit is controlled by the ECM. The ACV controls compressed air for each control valve. Air Inlet Temperature (AIT) sensor – A thermistor sensor that monitors intake air temperature. Ambient temperature – The environmental air temperature in which a unit is operating. In general, the temperature is measured in the shade (no solar radiation) and represents the air temperature for other engine cooling performance measurement purposes.

Brake Horsepower (bhp) – The power output from an engine, not the indicated horsepower. The power output of an engine, sometimes-called flywheel horsepower, is less than the indicated horsepower by the amount of friction horsepower consumed in the engine. Brake Horsepower (bhp) net – Net brake horsepower is measured with all engine components. The power of an engine when configured as a fully equipped engine. (SAE J1349 JUN90) Calibration – ECM programming strategy to solve engine performance equations and make decisions. Calibration values are stored in ROM and put into the processor during programming to allow the engine to operate within certain parameters. Camshaft Position (CMP) sensor – A magnetic pickup sensor that provides the ECM with a camshaft speed and position signal. Carbon Monoxide (CO) – A colorless, odorless, highly poisonous gas that is formed by the incomplete combustion of carbon burning diesel engine. It is present in the exhaust gases of diesel engines. Catalyst – A substance that produces a chemical reaction without undergoing a chemical change itself.


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Catalytic converter – An antipollution device in the exhaust system that contains a catalyst for chemically converting some pollutants in the exhaust gases (carbon monoxide, unburned hydrocarbons, and oxides of nitrogen) into harmless compounds. Cavitation – A dynamic condition in a fluid system that forms gas-filled bubbles (cavities) in the fluid. Cetane number – 1. diesel fuel.

The auto-ignition quality of

2. A rating applied to diesel fuel similar to octane rating for gasoline. 3. A measure of how readily diesel fuel starts to burn (self-ignites) at high compression temperature. Diesel fuel with a high cetane number self-ignites shortly after injection into the combustion chamber. Therefore, it has a short ignition delay time. Diesel fuel with a low cetane number resists self-ignition. Therefore, it has a longer ignition delay time. Charge air – Dense, pressurized, discharged from the turbocharger.

heated air

Charge Air Cooler (CAC) – See Aftercooler. Charge Air Outlet Temperature (CACOT) sensor – A thermistor sensor that monitors the temperature of charge air entering the intake air duct. Closed crankcase – A crankcase ventilation that recycles crankcase gases through a breather, then back to the clean air intake. Closed loop operation – A system that uses sensors to provide feedback to the ECM. The ECM uses the sensor input to continuously monitor variables and adjust actuators to match engine requirements. Cloud point – The point when wax crystals occur in fuel, making fuel cloudy or hazy. Usually below -12 °C (10 °F). Cold cranking ampere rating (battery rating) – The sustained constant current (in amperes) needed to produce a minimum terminal voltage under a load of 7.2 volts per battery after 30 seconds. Cold Start Fuel Ignitor (CSFI) – The CSFI heats the intake air by vaporizing and igniting fuel in the air inlet duct.

Cold Start Fuel Solenoid (CSFS) – As the engine is cranked, the ECM energizes the CSFS valve, introducing fuel into the CSFI, which ignites and warms the air being drawn into the engine. Cold Start Relay (CSR) – The CSR provides voltage to the CSFI, and is controlled by the ECM. Controller Area Network (CAN) – A J1939 high speed communication link. Coolant – A fluid used to transport heat from one point to another. Coolant level switch – A switch sensor used to monitor coolant level. Coolant Flow Valve (CFV) – The CFV is ECM controlled and redirects coolant through the fuel cooler, based on EFT, when directed. Coolant Mixer Valve (CMV) – Controls coolant flow through the low-temperature radiator. Continuous Monitor Test – An ECM function that continuously monitors the inputs and outputs to ensure that readings are within set limits. Crankcase – The housing that encloses the crankshaft, connecting rods, and allied parts. Crankcase breather – A vent for the crankcase to release excess interior air pressure. Crankcase Oil Separator Speed (CCOSS) sensor – The CCOSS sensor sends the ECM information about the speed of the crankcase oil separator internal components. Crankcase pressure – The force of air inside the crankcase against the crankcase housing. Crankshaft Position (CKP) sensor – A magnetic pickup sensor that determines crankshaft position and speed. Current – The flow of electrons passing through a conductor. Measured in amperes. Damper – A device that reduces the amplitude of torsional vibration. (SAE J1479 JAN85) Deaeration – The removal or purging of gases (air or combustion gas) entrained in coolant or lubricating oil.


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Deaeration tank – A separate tank in the cooling system used for one or more of the following functions:

Driver (low side) – A transistor within an electronic module that controls the ground to an actuator circuit.

•

Deaeration

•

Coolant reservoir (fluid expansion and afterboil)

•

Coolant retention

Dual Stage Turbocharger – An assembly of two turbochargers (low-pressure and high-pressure) in series to provide a wide range of charge air pressures efficiently.

•

Filling

•

Fluid level indication (visible)

Diagnostic Trouble Code (DTC) – 2010 model year vehicles no longer utilize DTC identification by number. DTCs are now identified using the Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI) identifiers only. Diesel Particulate Filter (DPF) – A diesel particulate filter, sometimes called a DPF, is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine. Diesel Oxidation Catalyst (DOC) – A DOC is part of the diesel exhaust Aftertreatment system. DOCs are devices that use a chemical process to break down pollutants in the exhaust stream into less harmful components. More specifically, DOCs utilize rare metals such as palladium and platinum to reduce hydrocarbon based Soluble Organic Fraction (SOF) and carbon monoxide content of diesel exhaust by simple oxidation. The DOC can be used during an active regeneration to create higher exhaust temperatures, thereby reducing soot in the DPF. Digital Multimeter (DMM) – An electronic meter that uses a digital display to indicate a measured value. Preferred for use on microprocessor systems because it has a very high internal impedance and will not load down the circuit being measured. Disable – A computer decision that deactivates a system and prevents operation of the system. Displacement – The stroke of the piston multiplied by the area of the cylinder bore multiplied by the number of cylinders in the engine. Down Stream Injection (DSI) – The DSI system injects fuel into the exhaust system to increase temperature of the exhaust gases, and is necessary for DPF regeneration. Driver (high side) – A transistor within an electronic module that controls the power to an actuator circuit.

Duty cycle – A control signal that has a controlled on/off time measurement from 0 to 100%. Normally used to control solenoids. EGR Cooler – A cooler that allows heat to dissipate from the exhaust gasses before they enter the intake manifold. Engine Control Module (ECM) – An electronic processor that monitors and controls the engine. Engine Back Pressure Valve (EBPV) – The ECM commands the EBPV to control the Exhaust Brake. Engine Compression Brake (ECB) valve – The ECB valve controls pressure entering the brake oil gallery from the high-pressure oil rail gallery. This activates the brake actuator pistons and opens the exhaust valves. Engine Compression Brake 1 (ECB1) solenoid – The ECB1 solenoid controls pressure entering the brake oil gallery from the high-pressure oil rail gallery. Engine Compression Brake 2 (ECB2) solenoid – The ECB2 solenoid controls pressure entering the brake oil gallery from the high-pressure oil rail gallery. Engine Compression Brake Pressure (ECBP) sensor – A high-pressure sensor that provides a feedback signal to the ECM indicating brake control pressure. Engine Coolant Level (ECL) sensor – A switch sensor that monitors coolant level. Engine Coolant Temperature 1 (ECT1) sensor – A thermistor sensor that detects engine coolant temperature. Engine Coolant Temperature 2 (ECT2) sensor – A thermistor sensor that detects engine coolant temperature. Engine Fuel Temperature (EFT) sensor – A thermistor sensor that measures fuel temperature. Engine lamp – An instrument panel lamp that comes on when DTCs are set. DTCs can be read as flash codes (red and amber instrument panel lamps).


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Engine OFF tests – Tests that are done with the ignition switch ON and the engine OFF. Engine Oil Pressure (EOP) sensor – A variable capacitance sensor that measures oil pressure. Engine Oil Temperature (EOT) sensor – A thermistor sensor that measures oil temperature. Engine rating – Engine rating includes Rated hp and Rated rpm. Engine RUNNING tests – Tests done with the engine running. Engine Throttle Valve (ETV) and Engine Throttle Position Sensor – The ETV valve is used to control airflow during a regeneration process of the aftertreatment system. The ETV valve is also used to ensure a smooth engine shut down by restricting airflow to the engine at shut down. Engine Warning Protection System (EWPS) – Safeguards the engine from undesirable operating conditions to prevent engine damage and to prolong engine life. Exhaust Back Pressure (EBP) – The pressure present in the exhaust system during the exhaust period. Exhaust Back Pressure Valve (EBPV) – A valve that regulates the amount of air pressure applied to the EBPV pneumatic actuator. Exhaust brake – A brake device using engine exhaust back pressure as a retarding medium. Exhaust Gas Recirculation (EGR) – A system used to recirculate a portion of the exhaust gases into the power cylinder in order to reduce oxides of nitrogen. Exhaust Gas Temperature (EGT) – The temperature of exhaust gases. Exhaust Gas Recirculation Temperature (EGRT) sensor – A thermistor sensor that detects the exhaust gas temperature entering the EGR cooler. Exhaust Gas Recirculation (EGR) valve – The EGRV controls the flow of exhaust gases to the intake manifold. The EGRV is integrated with an EGR Position (EGRP) sensor.

Exhaust Manifold Pressure (EMP) sensor – A variable capacitance sensor used to indicate air pressure in the exhaust manifold. Exhaust Manifold Temperature (EMT) sensor – A thermistor style sensor used to indicate air temperature in the exhaust manifold. Fault detection/management – An alternate control strategy that reduces adverse effects that can be caused by a system failure. If a sensor fails, the ECM substitutes a good sensor signal or assumed sensor value in its place. A lit amber instrument panel lamp signals that the vehicle needs service. Failure Mode Indicator (FMI) – Identifies the fault or condition effecting the individual component. Filter restriction – A blockage, usually from contaminants, that prevents the flow of fluid through a filter. Flash code – See Diagnostic Trouble Code (DTC). Fuel Delivery Pressure (FDP) sensor – A variable capacitance sensor that monitors fuel pressure coming from the fuel tank and sends a signal to the ECM. Fuel inlet restriction – A blockage, usually from contaminants, that prevents the flow of fluid through the fuel inlet line. Fuel pressure – The force fuel exerts on the fuel system as it is pumped through the fuel system. Fuel Pressure Control Valve (FPCV) – The FPCV controls the fuel pressure to the fuel rails and is controlled by the ECM. FPCV control depends on fuel pressure and fuel temperature. Fuel Rail Pressure (FRP) – The amount of pressure in the fuel rail. Fuel Rail Pressure (FRP) sensor – A variable capacitance sensor that monitors fuel pressure in the fuel rail and sends a signal to the ECM. Fuel strainer – A pre-filter in the fuel system that keeps larger contaminants from entering the fuel system.

Exhaust manifold – Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and are directed to the EGR cooler.


TERMINOLOGY Fuel Volume Control Valve (FVCV) – The FVCV regulates the volume of flow sent to the HPFP. The FVCV allows a sufficient quantity of fuel to be delivered to the HPFP depending on engine load, speed, injector quantity, fuel temperature, and number of injections per cycle. Fully equipped engine – A fully equipped engine is an engine equipped with only those accessories necessary to perform its intended service. A fully equipped engine does not include components that are used to power auxiliary systems. If these components are integral with the engine or, for any reason are included on the test engine, the power absorbed may be determined and added to the net brake power. (SAE J1995 JUN90) Fusible link (fuse link) – A fusible link is a special section of low tension cable designed to open the circuit when subjected to an extreme current overload. (SAE J1156 APR86) Gradeability – The maximum percent grade, which the vehicle can transverse for a specified time at a specified speed. The gradeability limit is the grade upon which the vehicle can just move forward. (SAE J227a) Gross Combined Weight Rating (GCWR) – Maximum combined weight of towing vehicle (including passengers and cargo) and the trailer. The GCWR indicates the maximum loaded weight that the vehicle is allowed to tow. Gross brake horsepower – The power of a complete basic engine, with air cleaner, without fan, and alternator, and air compressor not charging. H-Bridge Circuit – An H-Bridge (bipolar) circuit operates like putting a power source on one side of a motor and connecting the other side of the motor to a ground. This turns the motor. By shifting the leads on the motor, it will turn in the opposite direction.

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High Pressure Fuel Pump (HPFP) assembly – The HPFP is a volumetric pump that supplies fuel at high pressure. The HPFP is mounted in the rear valley on the top of the engine and is driven by the camshaft. High-pressure Piezo Common Rail (HPCR) – The HPFP pumps fuel through separate tubes to each fuel rail. Each fuel rail has four fuel tubes, one for each injector, that maintain constant pressure from the high-pressure pump to each injector. High speed digital inputs – Inputs to the ECM from a sensor that generates varying frequencies (engine speed and vehicle speed sensors). Horsepower (hp) – Horsepower is the unit of work done in a given period of time, equal to 33,000 pounds multiplied by one foot per minute. 1hp = 33,000 lb x 1 ft /1 min. Humidity Sensor (HS) – A sensor that measures the moisture content of filtered air entering the intake system. Hydrocarbons – Organic compounds consisting of hydrogen and carbon (fuel and oil). Hydrocarbon Injector – Injects fuel into the exhaust system to increase temperature of the exhaust gases. Injection Pressure Regulator (IPR) valve – A valve that is used to maintain desired injection control pressure. Injection Control Pressure (ICP) sensor – Provides a feedback signal to the ECM indicating injection control pressure. Inlet Air Heater (IAH) – The IAH is primarily used to assist in starting the engine during cold weather. In addition, it helps to reduce white smoke emissions by heating the incoming air. Intake manifold – Engine component that evenly supplies air to each intake port in the cylinder head(s).

Hall effect – The development of a transverse electric potential gradient in a current-carrying conductor or semiconductor when a magnetic field is applied.

Intake Manifold Pressure (IMP) sensor – A variable capacitance sensor used to indicate air pressure in the intake manifold.

Hall effect sensor – Transducer that varies its output voltage in response to changes in a magnetic field. Commonly used to time the speed of wheels and shafts.

Intake Manifold Temperature (IMT) sensor – A thermistor sensor used to indicate air temperature in the intake manifold.


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Internal Transfer Pump (ITP) – The ITP is part of the HPFP assembly and driven off the same shaft as the HPFP assembly. The ITP supplies fuel at a slightly higher pressure and flow to the HPFP though the Fuel Volume Control Valve (FVCV). The ITP also provides fuel for cooling and lubrication of the HPFP. Fuel is rerouted as pump return flow through the HPFP cooling and lubrication valve. Pressure is maintained at the inlet of the HPFP piston pump by an ITP regulator. International NGV Tool Utilized for Next Generation Electronics (INTUNE) – The diagnostics software for chassis related components and systems. Interstage Cooler (ISC) – Uses cooled coolant to lower the charged air temperature that exits from the turbocharger low-pressure compressor and enters the turbocharger high-pressure compressor. Low speed digital inputs – Switched sensor inputs that generate an on/off (high/low) signal to the ECM. The input to the ECM from the sensor could be from a high input source switch (usually 5 or 12 volts) or from a grounding switch that grounds the signal from a current limiting resistor in the ECM that creates a low signal (0 volts). Low temperature radiator thermostat – Coolant flow to the low temperature radiator is regulated by the low temperature radiator thermostat. Lubricity – Lubricity is the ability of a substance to reduce friction between solid surfaces in relative motion under loaded conditions. Lug (engine) – A condition when the engine is run at an overly low RPM for the load being applied. Manifold Absolute Pressure (MAP) – Boost pressure in the manifold that is a result of the turbocharger. Manifold Absolute Pressure (MAP) sensor – A variable capacitance sensor that measures boost pressure. Manometer – A double-leg liquid-column gauge, or a single inclined gauge, used to measure the difference between two fluid pressures. Typically, a manometer records in inches of water. Mass Air Flow – The intake airflow in an engine.

The ECM monitors the MAF signal so that the ECM can control the EGR and intake throttle systems. MasterDiagnostics® (MD) – Diagnostics software for engine related components and systems. Magnehelic Gauge – A gauge that measures pressure in inches of water. Magnetic Pickup Sensor – A magnetic pickup sensor generates an alternating frequency that indicates speed. Magnetic pickups have a two-wire connection for signal and ground. This sensor has a permanent magnetic core surrounded by a wire coil. The signal frequency is generated by the rotation of the gear teeth that disturb the magnetic field. Metering unit valve assembly – The Metering unit valve assembly provides a metered amount of fuel to the Aftertreatment Fuel Injector (AFI). Microprocessor – An integrated circuit in a microcomputer that controls information flow. Micro Strain Gauge (MSG) Sensor – A MSG sensor measures pressure. Pressure exerts force on a pressure vessel that stretches and compresses to change resistance of strain gauges bonded to the surface of the pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage output. Nitrogen Oxides (NOx) – Nitrogen oxides form by a reaction between nitrogen and oxygen at high temperatures and pressures in the combustion chamber. Normally closed – Refers to a switch that remains closed when no control force is acting on it. Normally open – Refers to a switch that remains open when no control force is acting on it. Ohm (Ω) – The unit of electrical resistance. One ohm is the value of resistance through which a potential of one volt will maintain a current of one ampere. (SAE J1213 NOV82) On demand test – A self-test the technician initiates using the EST that is run from a program in the software. Output Circuit Check (OCC) – An on-demand test done during an Engine OFF self-test to check the continuity of selected actuators.

Mass Air Flow (MAF) sensor – The MAF sensor is used for closed loop control of the EGR valve and ITV. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. © 2011 Navistar, Inc. All rights reserved

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pH – A measure of the acidity or alkalinity of a solution.

Ratiometric Voltage – In a Micro Strain Gauge (MSG) sensor, pressure to be measured exerts force on a pressure vessel that stretches and compresses to change resistance of strain gauges bonded to the surface of the pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage output.

Particulate matter – Particulate matter includes mostly burned particles of fuel and engine oil.

Reference voltage (VREF) – A 5 volt reference supplied by the ECM to operate the engine sensors.

Piezometer – An instrument for measuring fluid pressure.

Reserve capacity – Time in minutes that a fully charged battery can be discharged to 10.5 volts at 25 amperes.

Oxides of Nitrogen (NOx) – Nitrogen oxides formed by a reaction between nitrogen and oxygen at high temperatures. Oxygen Sensor (O2S) – A sensor that monitors oxygen levels in the exhaust.

Power – Power is a measure of the rate at which work (force x distance) is done during a specific time. Compare with Torque. Power TakeOff (PTO) – Accessory output, usually from the transmission, used to power a hydraulic pump for a special auxiliary feature (garbage packing, lift equipment, etc). Pulse Width Modulation (PWM) – Succession of digital electrical pulses, rather than an analog signal. Efficient method of providing power between fully on and fully off. Random Access Memory (RAM) – Computer memory that stores information. Information can be written to and read from RAM. Input information (current engine speed or temperature) can be stored in RAM to be compared to values stored in Read Only Memory (ROM). All memory in RAM is lost when the ignition switch is turned off. Rated gross horsepower – Engine gross horsepower at rated speed as declared by the manufacturer. (SAE J1995 JUN90) Rated horsepower – Maximum brake horsepower output of an engine as certified by the engine manufacturer. The power of an engine when configured as a basic engine. (SAE J1995 JUN90) Rated net horsepower – Engine net horsepower at rated speed as declared by the manufacturer. (SAE J1349 JUN90) Rated speed – The speed, as determined by the manufacturer, at which the engine is rated. (SAE J1995 JUN90)

Return Fuel System – The return fuel system moves unused fuel from the fuel injectors to the fuel cooler. Excess fuel out of the FVCV and the FPCV mix with fuel from the fuel injectors on the way to the fuel cooler. ServiceMaxx™ software – Diagnostics software for engine related components and systems. Signal Conditioner – The signal conditioner in the internal microprocessor converts analog signals to digital signals, squares up sine wave signals, or amplifies low-intensity signals to a level that the ECM microprocessor can process. Signal ground – The common ground wire to the ECM for the sensors. Speed Control Command Switches (SCCS) – A set of switches used for cruise control, Power TakeOff (PTO), and remote hand throttle system. Steady state condition – An engine operating at a constant speed and load and at stabilized temperatures and pressures. (SAE J215 JAN80) Strategy – A plan or set of operating instructions that the microprocessor follows for a desired goal. Strategy is the computer program itself, including all equations and decision making logic. Strategy is always stored in ROM and cannot be changed during calibration. Stroke – The movement of the piston from Top Dead Center (TDC) to Bottom Dead Center (BDC). Substrate – Material that supports the wash coating or catalytic materials.

Rated torque – Maximum torque produced by an engine as certified by the manufacturer.


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Suspect Parameter Number (SPN) – A 19-bit number used to identify the item for which diagnostics are being reported. The SPN is used for multiple purposes, some that are specific to diagnostics are as follows; •

Identify the least repairable subsystem that has failed.

•

Identify subsystems or assemblies that may not have hard failures but may be exhibiting abnormal operating performance.

•

Identify a particular event or condition that will be reported.

•

Report a component and non-standard failure mode.

System restriction (air) – The static pressure differential that occurs at a given airflow from air entrance through air exit in a system. Usually measured in inches (millimeters) of water. (SAE J1004 SEP81) Tachometer output signal – Engine speed signal for remote tachometers. Thermistor – A semiconductor device. A sensing element that changes resistance as the temperature changes. Thermistor Sensor – Changes electrical resistance with changes in temperature. Resistance in the thermistor decreases as temperature increases, and increases as temperature decreases. Thermistors work with a resistor that limits current to form a voltage signal matched with a temperature value. Thrust load – A thrust load pushes or reacts through a bearing in a direction parallel to the shaft. Top Dead Center (TDC) – The uppermost position of the piston during the stroke. Torque – A force having a twisting or turning effect. For a single force, the cross product of a vector from some reference point to the point of application of the force within the force itself. Also known as moment of force or rotation moment. Torque is a measure of the ability of an engine to do work. Truck Computer Analysis of Performance and Economy (TCAPE) – A computer program that simulates the performance and fuel economy of trucks.

Turbocharger – A turbine driven compressor mounted on the exhaust manifold. The turbocharger increases the pressure, temperature and density of intake air to charge air. Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor – A variable capacitance sensor that monitors exhaust back-pressure. Turbocharger 2 Compressor Inlet (TC2CIS) sensor – The TC2CIS sensor includes a thermistor sensor that monitors the temperature of charge air entering the HP turbocharger. This sensor also monitors boost pressure for the LP turbocharger. Turbocharger Wastegate Control (TCWC) solenoid – Controls the TCWC actuator by regulating the amount of charge air pressure supplied to the TCWC actuator. The TCWC solenoid is controlled by signals from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude. Turbocharger 1 Wastegate Control (TC1WC) solenoid – Controls the TC1WC actuator by regulating the amount of charge air pressure supplied to the TC1WC actuator. The TC1WC solenoid is controlled by signals from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude. The TC1WC actuator is part of the turbocharger assembly. Turbocharger 2 Wastegate Control (TC2WC) solenoid – Controls the TC2WC actuator by regulating the amount of charge air pressure supplied to the wastegate actuator. The TC2WC solenoid is controlled by signals from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude. The TC2WC actuator is part of the turbocharger assembly. Variable capacitance sensor – A variable capacitance sensor measures pressure. The pressure forces a ceramic material closer to a thin metal disc in the sensor, changing the capacitance of the sensor. Vehicle Electronic System Programming System – The computer system used to program electronically controlled vehicles. Vehicle Retarder Enable/Engage – Output from the ECM to a vehicle retarder.


TERMINOLOGY Vehicle Speed Sensor (VSS) – Normally a magnetic pickup sensor mounted in the tailshaft housing of the transmission, used to indicate ground speed. Viscosity – The internal resistance to the flow of any fluid. Viscous fan – A fan drive that is activated when a thermostat, sensing high air temperature, forces fluid through a special coupling. The fluid activates the fan. Volt (v) – A unit of electromotive force that will move a current of one ampere through a resistance of one Ohm.

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Voltage – Electrical potential expressed in volts. Voltage drop – Reduction in applied voltage from the current flowing through a circuit or portion of the circuit current multiplied by resistance. Voltage ignition – Voltage supplied by the ignition switch when the key is ON. Washcoat – A layer of alumina applied to the substrate in a monolith-type converter. Water In Fuel (WIF) sensor – A switch sensor that measures the amount of water in the fuel.


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APPENDIX A – SPECIFICATIONS

461

Table of Contents

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463 Oil Pump, Low Mount Fan Drive, and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464 Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464 Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466


462




463

Fuel System Table 46

Fuel System

Fuel strainer filtration

300 microns

Fuel filter element filtration

3-5 microns

Air Inlet Duct and Exhaust Manifolds Table 47

Exhaust Manifolds

Exhaust manifold maximum allowable warpage

0.1 mm (0.003 in)

Engine Brake Table 48

Engine Brake

Solenoid resistance: Cold – 8.7–10 ohms

Cold — 25° C (77° F) Hot — 121° C (250° F)

0.1 mm (0.003 in)

12–15.5 ohms

Cylinder Head, Camshaft and Valve Train Table 49


Camshaft Camshaft bearing inside diameter Camshaft end play

39.925 – 39.950 mm (1.57185 – 1.57283 in) 0.25 – 0.85 mm (0.0098 – 0.0334 in)

Valve Lash Adjustment Exhaust valve clearance

0.8 mm (0.0315 in)

Intake valve clearance

0.5 mm (0.0197 in)

Cylinder Head Idler Gear Cup Plug Cup plug, DMR 63.10

Recess 2.3 mm (0.9 in)

Flywheel and Flywheel Housing Table 50


Flywheel minimum thickness (dimension “A”) Flywheel maximum surface runout

46 mm (1.811 in) 0.20 mm (0.0079 in)



464

Oil Pump, Low Mount Fan Drive, and Timing Gears Table 51

Oil Pump, Low Mount Fan Drive, and Timing Gears

Front Timing Gears Front intermediate gear backlash

0.057 - 0.183 mm (0.0022 - 0.0072 in)

Oil Pump Oil pump pinion and oil pump ring gear end play

0.0030 - 0.120 mm (0.0012 - 0.0047 in)

Rear Timing Gears Big intermediate gear backlash

0.052 - 0.176 mm (0.0020 - 0.0069 in)

Crankcase intermediate gear backlash

0.052 - 0.176 mm (0.0020 - 0.0069 in)

Power Cylinders Table 52

Power Cylinders

Connecting Rods Piston pin bore inside diameter Connecting rod bearing bore diameter (crankshaft end)

52.06 ± 0.005 mm (2.0496 ± 0.0001 in)

95.000 to 95.022 mm (3.7402 to 3.7402 in)

Pistons — 11L Skirt diameter measured 16 mm from piston bottom edge, 90° to piston pin axis in “window” on skirt graphite layer, where applicable Piston protrusion measured from crankcase deck to piston Piston pin bore inside diameter, measured vertically, 38 mm from piston center Piston pin running clearance

119.88 ± 0.009 mm (4.7197 ± 0.0004 in)

0.3 ± 0.22 mm (0.0118 ± 0.009 in)

52.010 - 52.016 mm (2.0476 - 2.0479 in) 0.010 - 0.024 mm (0.0004 - 0.0009 in)

Pistons — 13L Skirt diameter measured 26.9 mm from piston bottom edge, 90° to piston pin axis in “window” on skirt graphite layer, where applicable Piston protrusion measured from crankcase deck to piston

125.950 ± 0.013 mm (4.9587 ± 0.0005 in)

0.3 ± 0.22 mm (0.0118 ± 0.009 in)

Piston pin bore inside diameter, measured horizontally 26 mm from piston center

52.04 - 52.05 mm (2.0490 - 2.0492 in)

Piston pin running clearance

0.040 - 0.058 mm (0.0016 - 0.0023 in)



Table 52

465

Power Cylinders (cont.)

Piston Pins Outside diameter

51.992 - 52.000 mm (2.0469 - 2.0472 in)


0.4 - 0.55 mm (0.0157 - 0.0217 in)


1.00 - 1.20 mm (0.0393 - 0.0472 in)

Side clearance

0.09 - 0.13 mm (0.0035 - 0.0051 in)


0.25 - 0.50 mm (0.0098 - 0.0197 in)

Side clearance

0.03 - 0.07 mm (0.0012 - 0.0028 in)


0.4 - 0.55 mm (0.0157 - 0.0217 in)


1.00 - 1.20 mm (0.0394 - 0.0472 in)

Side clearance

0.09 - 0.13 mm (0.0035 - 0.0051 in)


0.25 - 0.50 mm (0.0098 - 0.0197 in)

Side clearance

0.05 - 0.09 mm (0.0020 - 0.0035 in)


0.050 - 0.085 mm (0.0019 - 0.0033 in) 120 ± 0.01 mm (4.7244 ± 0.0004 in)


0.050 - 0.085 mm (0.0019 - 0.0033 in) 126 ± 0.01 mm (4.9606 ± 0.0004 in)



466 Crankcase and Crankshaft Table 53


Crankshaft Main Bearing: Journal diameter Installed bearing inside diameter Uninstalled bearing outside diameter (free spread)

103.98 - 104.00 mm (4.0937 - 4.0945 in) 104.044 - 104.09 mm (4.0962 - 4.0980 in) 111.20 - 112.40 mm (4.3779 - 4.4252 in)

Connecting Rod Bearing: Journal diameter

89.98 - 90.00 mm (3.5425 - 3.5433 in)

Crankshaft end play: Maximum service

0.200 - 0.401 mm (0.0079 - 0.0158 in)


APPENDIX B – TORQUES

467

Table of Contents

General Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469 Bolt Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469 General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 Standard Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471 Using a Torque Wrench Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472 Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473 Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473 Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473 Cold Start Assist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474 Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474 Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475 Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475 Air Compressor and Power Steering/Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477 Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478 Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478 Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479 Front Cover, High Mount Fan Drive, Cooling System, Related Components. . . . . . . . . . . . . . . . . . . . . .480 Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481 Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482 Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483 Oil Pan and Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484 Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485 Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485 Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485


468




General Torque Bolt Identification

Figure 600

Metric fasteners – Classification and identification

Figure 601

Special fasteners – Classification and identification


469


470 General Torque Guidelines

CAUTION: To prevent engine damage, do not substitute fasteners. All original equipment fasteners are hardened and phosphate coated. NOTE: Inspect parts for cleanliness and defects before assembly. Many conditions affect torque and the results of torque applications. The major purpose in tightening a fastener to a specified torque is to obtain a clamping load which exceeds any possible loading imposed on parts. New phosphate coated fasteners do not require oil lubrication during assembly and torque application. Reused fasteners (even if originally phosphate

coated) do require oil lubrication to threads and under head area for correct torque application. Threads that are dry, excessively rough, battered, or filled with dirt require considerable effort just to rotate. Then when the clamping load is developed or the bolt tension is applied, the torque reading mounts rapidly (due to thread friction) to the specified torque value. However, the desired bolt tension and correct clamping load is not achieved. This condition can lead to failure of the fastener to maintain component integrity. The correct bolt tension and clamping effect can never be attained if the fastener is dry. Fastener threads must be new condition phosphate coated or have a film of clean lubricant (engine oil) to be considered lubricated.



471

Standard Torque Charts CAUTION: To prevent engine damage, do not use this standard torque chart with other International brand engines or engines made by other manufacturers. Standard torque chart provides tightening values for all hardware that do not require special torque. Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs Thread Diameter (mm)

Thread Pitch (mm)

Torque

6

1

13 N·m (115 lbf·in)

8

1.25

31 N·m (23 lbf·ft)

10

1.5

62 N·m (45 lbf·ft)

12

1.75

107 N·m (79 lbf·ft)

14

2

172 N·m (127 lbf·ft)

15

2

216 N·m (159 lbf·ft)

16

2

266 N·m (196 lbf·ft)

18

2.5

368 N·m (272 lbf·ft)

20

2.5

520 N·m (384 lbf·ft)

Example: Tighten four M6 x 12 pulley bolts to standard torque. What is the size and standard torque for these four bolts? M6 x 12 refers to the bolts thread diameter and length. These bolts have a thread diameter of 6 mm and are 12 mm long.

To find the standard torque for a M6 x 12 bolt look at the torque chart above. We see the standard torque for a 6 mm thread diameter class 10.9 bolt should be 13 N·m (115 lbf·in).



472 Using a Torque Wrench Extension

Occasionally an extension, crowfoot, or other adapter is necessary to use with a torque wrench to torque a bolt or line fitting. Adding adapters or extensions will alter the torque on the fastener from what the torque wrench reads. Use the following formula to calculate the correct torque wrench setting to achieve a specific torque value.

Figure 602

Torque wrench and extension

•

F - Force applied by technician

•

L - Total length through which force is applied to fastener

•

TW - Torque applied at end of torque wrench

TS = TE (LW / (LW + LE))

reach it. What should the torque wrench setting (TS) be to compensate for the extension? •

Torque specified at fastener (TE) = 65 lbf·ft

•

Length of torque wrench (LW) = 12 inches

•

Length of extension (LE) = 6 inches

•

TS - Torque wrench setting

TS = TE (LW / (LW + LE))

•

TE - Torque specified at fastener

TS = 65 lbf·ft (12 inches / (12 inches + 6 inches)

•

LW - Length of torque wrench

TS = 65 lbf·ft (12 inches / (18 inches)

•

LE - Length of extension

TS = 65 lbf·ft (0.666)

Example: A component requires a specified torque value of 65 lbf·ft and a 6 inch extension is required to

TS = 43.33 lbf·ft



473

Special Torques Mounting Engine on Stand Table 54


M14 x 50 engine front mount support bolts Oil drain plug

225 N·m (166 lbf·ft) 75 N·m (55 lbf·ft)

Engine Electrical Table 55

Engine Electrical

Camshaft Position (CMP) sensor, M6 x 12 bolt

8 N·m (71 lbf·in)

Charger Air Cooler Outlet Temperature (CACOT) sensor

11 N·m (97 lbf·in)

Crankcase Oil Separator Speed (CCOSS) sensor, M6 x 14 bolt

10 N·m (89 lbf·in)

Crankshaft Position (CKP) sensor, M6 x 16 bolt Engine Control Module (ECM), M6 x 30 bolt

8 N·m (71 lbf·in) 10 N·m (89 lbf·in) See procedure for tightening sequence

Engine Control Module (ECM) support, M8 x 40 bolt

35 N·m (26 lbf·ft)


45 N·m (33 lbf·ft)


45 N·m (33 lbf·ft)

Engine injector harness retainer clip, M6 x 30 bolt

10 N·m (89 lbf·in)

Engine Oil Pressure (EOP) sensor

45 N·m (33 lbf·ft)

Engine Oil Temperature (EOT) sensor

45 N·m (33 lbf·ft)

Engine sensor harness bracket/clip, M8 x 16 bolt

35 N·m (26 lbf·ft)

Exhaust Gas Recirculation Temperature (EGRT) sensor

37 N·m (27 lbf·ft)

Fuel Delivery Pressure (FDP) sensor

45 N·m (33 lbf·ft)

Humidity / Air Inlet Temperature (AIT) sensor, M6 x 16 bolt Intake Manifold Temperature (IMT) sensor

9 N·m (80 lbf·in) 45 N·m (33 lbf·ft)

Intake Manifold Pressure (IMP) sensor

12 N·m (106 lbf·in)

Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw

0.36 N·m (3 lbf·in)

Oxygen Sensor (O2S) Rail Fuel Pressure (RFP) sensor Turbocharger 2 Compressor Inlet Sensor (TC2CIS), M6 x 16 bolt

50 N·m (37 lbf·ft) 140 N·m (103 lbf·ft) 9 N·m (80 lbf·in)



474 Cold Start Assist Table 56

Cold Start Assist

Banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts

15 N·m (11 lbf·ft)

Banjo M8 x 1 bolt

8 N·m (71 lbf·in)

Fuel supply cold start hose fitting nut

10 N·m (11 lbf·ft)

Glow plug locking nut

25 N·m (18 lbf·ft)

Relay assembly M6 x 20 bolts

10 N·m (89 lbf·in)

Solenoid valve M6 x 20 bolts

6 N·m (53 lbf·in)

Aftertreatment System Table 57


Coolant supply (straight) fitting at coolant manifold

35 N·m (26 lbf·ft)

Fitting (quick-connect adapter) at metering unit valve assembly

35 N·m (26 lbf·ft)

Fitting (straight union orifice) at metering unit valve assembly

35 N·m (26 lbf·ft)

HCI coolant supply and return tube nut at tube M10 elbow fittings

15 N·m (11 lbf·ft)

HCI coolant supply tube nut at coolant manifold

25 N·m (18 lbf·ft)

HCI fuel 1 tube assembly nut at HCI fuel 2 tube fitting (brazed)

25 N·m (18 lbf·ft)

HCI fuel 1 tube assembly nut at metering unit valve assembly

25 N·m (18 lbf·ft)

HCI fuel 2 tube assembly nut at hydrocarbon injector

18 N·m (13 lbf·ft)

Hydrocarbon injector M8 x 45 bolt


Hydrocarbon injector body to assembly (if accidentally loosened during fuel tube nut service)

20 N·m (15 lbf·ft)

Metering unit bracket bolt, M8 x 16

31 N·m (23 lbf·ft)

Tube M10 elbow fittings at hydrocarbon injector

17.5 N·m (13 lbf·ft)



475

Exhaust Back Pressure Control Table 58


Air supply tube (at bulkhead fitting)

17.5 N·m (13 lbf·ft)

Air supply tube nut (at air control valve)

12 N·m (106 lbf·in)

Exhaust back pressure valve assembly mounting bolts, M8 x 45 Exhaust back pressure valve tube nut (at actuator)

25 N·m (18 lbf·ft)

Exhaust back pressure valve tube nut (at air control valve) Flare M10 x M12 (24 degree) fitting

15 N·m (11 lbf·ft)

15 N·m (11 lbf·ft)

17.5 N·m (13 lbf·ft)

TC1TOP sensor tube nut (at air control valve)

15 N·m (11 lbf·ft)

TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting

15 N·m (11 lbf·ft)

Turbochargers Table 59

Turbochargers

3/4 inch and 1 inch worm gear hose clamps

3.5 N·m (31 lbf·in)

High-pressure-to-low-pressure turbine bolts, M10 x 55

47 N·m (35 lbf·ft)

Low-pressure and high-pressure wastegate actuator bolts, M8 x 14

16 N·m (12 lbf·ft)

Male stud connector

70 N·m (52 lbf·ft)

M24 threaded fitting

60 N·m (44 lbf·ft)

Oil return low-pressure turbocharger tube (at crankcase)


Oil return low-pressure turbocharger tube fitting nut


Turbocharger oil supply tube assembly fitting nut to male stud connector

27 N·m (20 lbf·ft)



476

Air Compressor and Power Steering/Fuel Pump Table 60

Air Compressor and Power Steering/Fuel Pump

1-1/16" 90 degree elbow lock nut

55 N·m (40 lbf·ft)

1/2" 90 degree tube elbow lock nut

45 N·m (33 lbf·ft)

Air compressor M8 x 40, M8 x 110 bolt (one cylinder)

35 N·m (26 lbf·ft)

Air compressor M8 x 40, M8 x 110 bolt (two cylinder)

31 N·m (23 lbf·ft)

(Two cylinder) Air compressor M10 x 110 bolt

67 N·m (49 lbf·ft)

High-pressure tube fitting nut

62 N·m (45 lbf·ft)


35 N·m (26 lbf·ft)

M16 45° fitting

17.5 N·m (13 lbf·ft)


37.5 N·m (28 lbf·ft)

Low-pressure tube fitting nut

164 N·m (120 lbf·ft)

Power steering pump M10 x 40 bolt

67 N·m (49 lbf·ft)



477


Fuel System

Banjo bolt, M14

30 N·m (22 lbf·ft)

Check valve

35 N·m (26 lbf·ft)

Fuel drain line fitting nut

26 N·m (19 lbf·ft)

Fuel filter bracket M8 x 30 bolt

35 N·m (26 lbf·ft)

Fuel filter housing assembly M8 x 45 bolt

35 N·m (26 lbf·ft)

Fuel filter cap

25 N·m (18 lbf·ft)

Fuel filter stand pipe

12 N·m (106 lbf·in)

Fuel primer pump M8 x 25 bolt

30 N·m (22 lbf·ft)

Fuel rail M8 x 40 bolt

35 N·m (26 lbf·ft)

Fuel strainer cover

10 N·m (89 lbf·in)

Fuel supply adapter

30 N·m (22 lbf·ft)

High-pressure connector (body) retaining nut High-pressure fuel pump drive housing M12 x 40, M12 x 90, M12 x 130 bolt High-pressure fuel pump M10 x 40 bolt

See tightening steps in procedure 105 N·m (77 lbf·ft) 62 N·m (46 lbf·ft)

High-pressure fuel pump M24 jam nut

285 N·m (210 lbf·ft)

High-pressure fuel pump support M14 x 30 bolt

172 N·m (126 lbf·ft)

High-pressure pump to rail tube assembly line fitting nuts


High-pressure rail to injector line fitting nut


High-pressure pump pulley housing M10 x 40 bolt High-pressure pump pulley M16 x 40 LH bolt Injector harness nut Injector hold-down clamp M8 x 50 bolt

62 N·m (46 lbf·ft) 280 N·m (207 lbf·ft) 1.5 N·m (13 lbf·in) See tightening steps in procedure

Quick-connect M16 x 1.5 connector

30 N·m (22 lbf·ft)

Threaded unions (M14 x 1.5)

30 N·m (22 lbf·ft)



478 Oil Module Assembly Table 62

Oil Module Assembly

Heater return tube assembly bolt, M6 x 16

13 N·m (115 lbf·in)

Heater return tube assembly tube nut

11 N·m (97 lbf·in)

Oil cooler bolts, M8 x 45 and M8 x 90

25 N·m (18 lbf·ft)

Oil filter cover

40 N·m (30 lbf·ft)

Oil module assembly bolts, M10 x 80, M10 x 170 and M10 x 110

65 N·m (48 lbf·ft)

Oil module flange bolts, M8 x 45

24 N·m (18 lbf·ft)


40 N·m (30 lbf·ft)

Open breather tube assembly bolt, M6 x 16 Water pump bolt, M8 x 150 (front side of oil module)

13 N·m (115 lbf·in) 35 N·m (26 lbf·ft)

Exhaust Gas Recirculation (EGR) System Table 63

EGR System

Coolant manifold, M8 x 45 bolt and M8 x 50 x 16 stud bolt

35 N·m (26 lbf·ft)

EGR cooler assembly mounting bolts, M10 x 45 and M10 x 70 EGR dual flap valve, M8 x 30 heat-resistant bolt

62 N·m (46 lbf·ft)

EGR inlet (cylinders 4-6) tube, M8 x 25 heat-resistant bolt EGR inlet (cylinders 1-3) tube, M8 x 25 heat-resistant bolt EGR outlet tube hose clamps

24 N·m (18 lbf·ft)

EGR valve coolant supply tube nut

26 N·m (19 lbf·ft)

24 N·m (18 lbf·ft)

24 N·m (18 lbf·ft) 5 N·m (45 lbf·in)



479

Air Inlet Duct and Exhaust Manifolds

Figure 603 sequence

Table 64

Exhaust manifold tightening


Air intake throttle duct bolts, M8 Exhaust manifold Torx® bolts, M10 x 57

31 N·m (23 lbf·ft) See tightening procedure and sequence in steps


480


Front Cover, High Mount Fan Drive, Cooling System, Related Components

Figure 604 sequence

High mount fan drive bolt tightening


APPENDIX B – TORQUES Table 65

481


Automatic belt tensioner countersunk screw, M10 x 70

47 N·m (35 lbf·ft)

CCV assembly stud bolts (with lock washers), M8 x 60

35 N·m (26 lbf·ft)

Coolant heater

41 N·m (30 lbf·ft)

Coolant outlet manifold bolts, M8

35 N·m (26 lbf·ft)

Damper hub and fan drive pulley bolts to vibration damper, M10 x 35

45 N·m (33 lbf·ft)

EGR cooler return manifold bolts, M8

35 N·m (26 lbf·ft)

Engine water inlet bolts, M10 x 30

29 N·m (21 lbf·ft)

Front belt- or gear-driven fan cover bolts, •

M8

•

M12 x 75

115 N·m (85 lbf·ft)

•

M12 x 30

115 N·m (85 lbf·ft)

31 N·m (23 lbf·ft)

High mount fan drive clutch assembly bolts, M10


High mount fan drive tensioner countersunk screw, M10 x 70

47 N·m (35 lbf·ft)

High mount fan pulley assembly shoulder bolt

62 N·m (46 lbf·ft)

Idler pulley bolt, M12 x 55

60 N·m (44 lbf·ft)

Low mount fan drive bolt, M10 x 110

37 N·m (27 lbf·ft)

Thermostat housing bolts, M8

35 N·m (26 lbf·ft)

Vibration damper socket-head cap screws, M16 x 85


Water distribution housing bolts, M8

35 N·m (26 lbf·ft)

Water pump assembly bolts, M8

35 N·m (26 lbf·ft)

Water pump pulley bolts, M8 x 16

17 N·m (13 lbf·ft)

Engine Brake Table 66

Engine Brake

Brake housing M10 x 90 bolt

75 N·m (55 lbf·ft)

Brake housing M12 x 100 (socket-head) screw

105 N·m (77 lbf-ft)

Brake housing solenoid harness connector nut

3.5 N·m (31 lbf·in)

Slave piston adjusting screw M10 (jam) nut Solenoid M6 x 10 socket-head cap screw

25 N·m (18 lbf·ft) 12.5 N·m (110 lbf·in)



482


Figure 605

Table 67

Cylinder head bolts tightening sequence


Camshaft gear M8 x 30 bolt


(Camshaft) bearing cap M8 x 35 bolt

25 N·m (18 lbf·ft)

Cylinder head idler gear M8 x 30 socket-head cap screw

30 N·m (22 lbf·ft)

Cylinder head M18 x 246 Torx® bolt Rocker arm assembly M12 x 60 (socket-head) screw


Upper valve cover M8 x 30 bolt

10 N·m (89 lbf·in)

Valve cover base screw with damper

11 N·m (97 lbf·in)

Valve lash adjustment M10 nut

45 N·m (33 lbf·ft)



483


Figure 606

Table 68

Flywheel bolt tightening sequence


12PT flange bolts Flywheel housing bolts, M10 x 30 and M10 x 40 Lifting eye bolts, M16 x 150 Timing hole cover screws

See tightening steps in procedure. 65 N·m (48 lbf·ft) 280 N·m (207 lbf·ft) 2 N·m (18 lbf·in)



484 Oil Pan and Oil Suction Tube

Figure 607

Table 69

Torque sequence

Oil Pan Components

Drain plug, M27 x 2

75 N·m (55 lbf·ft)

Oil pan bolts, M8 x 40

35 N·m (26 lbf·ft)

Oil pan heater element or replacement drain plug

75 N·m (55 lbf·ft)



485

Oil Pump and Timing Gears Table 70


Air compressor coupled idler gear, M12 x 55 bolts

107 N·m (79 lbf·ft)

Axle for pinion (oil pump), M10 x 35 socket-head cap screw

65 N·m (48 lbf·ft)

Crankcase idler gear, M8 x 30 socket-head cap screws

30 N·m (22 lbf·ft)

(Front) idler gear, M12 x 50 socket-head cap screws Idler large gear, M14 x 80 bolts

105 N·m (77 lbf·ft) 175 N·m (129 lbf·ft)


Power Cylinders

Connecting rod bolts Sleeve Protrusion Hold Down Clamp bolts


Crankcase and Crankshaft Table 72


Collar bolts (main bearing cap), M18 x 160.5 Piston cooling jet bolts, M6 x 12

See tightening procedure and sequence 13 N·m (115 lbf·in)


486



APPENDIX C – SPECIAL SERVICE TOOLS

487

Table of Contents

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489 Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489 Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489 Cold Start Assist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489 Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489 Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490 Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490 Air Compressor and Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491 Oil Cooler, Filter Housing and Crankcase Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491 Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491 Air Inlet Throttle Duct and Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492 Front Cover, Fan Drive, Cooling System and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492 MaxxForce Engine Brake by Jacobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492 Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493 Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493 Oil Pump, Fan Drive and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494 Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494 Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495 Essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495


488




489

Special Tools Special tools for the MaxxForce® 11 and 13 engines with ZTSE numbers can be ordered from the SPX Corporation, 1-800-520-2584.

Mounting Engine on Stand Table 73


Description

Tool Number


ZTSE4891

Engine Stand Adapter Plate

ZTSE4789

Engine Electrical Table 74

Engine Electrical

Description

Tool Number


ZTSE4891

Cold Start Assist Table 75

Cold Start Assist

Description

Tool Number

Aftertreatment System Table 76


Description

Tool Number


ZTSE4773

Hydrocarbon Injector Flow Test Kit

ZTSE6069


Obtain locally



490

Exhaust Back Pressure Control Table 77


Description

Tool Number

Crimping pliers

Obtain locally

Superlub™ synthetic high heat lubricant

Obtain locally

Turbochargers Table 78

Turbochargers

Description

Tool Number

3-inch couplers and clamps

Obtain locally

Charge Air Cooler Test Kit Crimping pliers


Extension Tube Installer P-80® rubber lubricant or equivalent


Turbo Alignment Bracket

ZTSE6041

Air Compressor and Power Steering Table 79


Description

Tool Number

Coolant Line Release Tool

ZTSE4778

Loctite® 5900 sealant or Wacker® A-442 RTV

Obtain locally

P80® rubber lubricant or equivalent

Obtain locally



491


Fuel System

Description

Tool Number

Crowfoot wrench

Obtain locally


ZTSE4891

Fan Hub/High Pressure Drive Seal Installer

ZTSE6066

Fuel Injector Cups

ZTSE4892

Fuel Injector Rack Holder

ZTSE4299B

Fuel Injector Tip Cleaning Brush

ZTSE4301


ZTSE4773

Injector Installer

ZTSE4777

Injector Puller

ZTSE4770


ZTSE4751


Obtain locally

Slide hammer

Obtain locally

Oil Cooler, Filter Housing and Crankcase Ventilation Table 81

Oil Cooler, Filter Housing and Crankcase Ventilation

Description

Tool Number


Obtain locally


ZTSE6051-1


ZTSE6051-2

Engine Oil Cooler Pressure Test Plate P-80® rubber lubricant or equivalent


Exhaust Gas Recirculation (EGR) System Table 82


Description

Tool Number


Obtain locally

EGR Cooler Pressure Test Kit

KL 20060 NAV


ZTSE6046


ZTSE6047


Obtain locally



492

Air Inlet Throttle Duct and Exhaust Manifold Table 83

Air Inlet Throttle Duct and Exhaust Manifold

Description

Tool Number

Feeler gauge

Obtain locally

FEY Rings Installation Tools

ZTSE6030

Straightedge

Obtain locally


Obtain locally

Front Cover, Fan Drive, Cooling System and Related Components Table 84


Description

Tool Number


ZTSE6046


ZTSE6047

Fan Seal Installer

ZTSE6066

Front Crankshaft Seal Installer

ZTSE4873


Obtain locally

Slide hammer

Obtain locally

MaxxForce Engine Brake by Jacobs Table 85

MaxxForce Engine Brake by Jacobs

Description

Tool Number

Jacobs® Slave Piston Removal Tool


ZTSE6068


493

Cylinder Head, Camshaft and Valve Train Table 86


Description

Tool Number


Obtain locally

Bearing installer

Obtain locally


ZTSE4869


Obtain locally

Feeler gauge (standard)

Obtain locally

Feeler gauge (Jacobs® 96-020949)

Obtain from Jacobs

Head Bolt Bottoming Tap

ZTSE4855

Head Bolt Torx® Socket

ZTSE4835


ZTSE4751

™

Loctite® 262 Threadlocker

Obtain locally

Loctite® 5900 sealant or equivalent

Obtain locally

M8 x 20 class 10.9 bolts

Obtain locally

Telescoping gauge set

Obtain locally

Flywheel and Flywheel Housing Table 87


Description

Tool Number

1-2 inch micrometer

Obtain locally

Blind hole puller

Obtain locally

Brake cleaner (non-caustic)

Obtain locally


Obtain locally

Loctite 5900®

Obtain locally

Wacker® A–442 RTV sealant

Obtain locally


ZTSE4898

Rear Oil Seal Installer

ZTSE4875

Slide hammer

Obtain locally



494

Oil Pump, Fan Drive and Timing Gears Table 88

Oil Pump, Fan Drive and Timing Gears

Description

Tool Number


Obtain locally

Feeler gauge

Obtain locally

Gear puller

Obtain locally


Power Cylinders

Description

Tool Number


Obtain locally


Obtain locally


Obtain locally

Connecting Rod Bolt Torx® Socket

ZTSE4843

Cylinder Sleeve Puller

ZTSE2536

Dial bore gauge

Obtain locally


Obtain locally

Feeler gauge

Obtain locally

Piston ring compressor

Obtain locally

Piston ring expansion pliers

Obtain locally

Sleeve Protrusion Hold Down Clamps Telescoping gauge


Crankcase and Crankshaft Table 90


Description

Tool Number


Obtain locally


Obtain locally

Dial bore gauge

Obtain locally


Obtain locally

Head Bolt Bottoming Tap Lifting sling


Main Bolt Bottoming Tap


ZTSE4854


495

Special Tools Essential Tools Figure 608 Test Kit

KL 20060 NAV EGR Cooler Pressure

Figure 609

ZTSE 6060 Engine Rotating Tool

Figure 610

ZTSE2536 Cylinder Sleeve Puller

Figure 611 Holder

ZTSE4299B Fuel Injector Rack

Figure 612 Brush

ZTSE4301 Fuel Injector Tip Cleaning

Figure 613

ZTSE4751 Injector Sleeve Brushes

Figure 614

Figure 615 11.8 mm

ZTSE4773 fuel line disconnect tool

Figure 616

ZTSE4777 injector installer

ZTSE4770 injector puller


496


Figure 617

ZTSE4778 coolant line release tool

Figure 618 Plate

ZTSE4789 Engine Stand Adapter

Figure 620

ZTSE4835 Head Bolt Torx Socket

Figure 621 Socket

ZTSE4843 Connecting Rod Bolt Torx

Figure 619 ZTSE4825 Sleeve Protrusion Hold Down Clamps



Figure 622

ZTSE4854 Main Bolt Bottoming Tap

Figure 623

ZTSE4855 Head Bolt Bottoming Tap

497

Figure 624 Bracket

ZTSE4869 Cylinder Head Lifting

Figure 625 Installer

ZTSE4873 Front Crankshaft Seal


498

Figure 626 Caps

Figure 627


ZTSE4891 Disposable Air and Fuel

Figure 628 Tool

ZTSE4898 Pilot Bearing Installation

Figure 629 Tools

ZTSE6030 FEY Rings Installation

Figure 630 Kit

ZTSE6042 Charger Air Cooler Test

ZTSE4892 Fuel Injector Caps (6)



Figure 631

ZTSE6043 Extension Tube Installer

Figure 632 Large


Figure 633 Small


499

Figure 634 Large

ZTSE6051–1 Extension Tube Installer

Figure 635 Small

ZTSE6051–2 Extension Tube Installer


500


Figure 636 ZTSE6063 Engine Oil Cooler Pressure Test Plate

Figure 637 ZTSE6066 Fan Hub/High Pressure Drive Seal Installer

Figure 638 ZTSE6069 Hydrocarbon Injector Flow Test Kit


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